Manual HD605-8

SEN06605-11
DUMP TRUCK HD465 -8

HD605 -8
HD465- 8 30001 and up
SERIAL NUMBERS
HD605- 8 30001 and up
00 INDEX AND FOREWORD
HD465-8, HD605-8 00-1

INDEX 00 INDEX AND FOREWORD
INDEX
00 INDEX AND FOREWORD - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-1
ABBREVIATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-24
FOREWORD, SAFETY, BASIC INFORMATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-29
HOW TO READ THE SHOP MANUAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-29
SAFETY NOTICE FOR OPERATION- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-31
PRECAUTIONS TO PREVENT FIRE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-39
ACTIONS IF FIRE OCCURS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-40
PRECAUTIONS FOR REMOVAL OF DANGEROUS MATERIALS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-40
STEPS NECESSARY TO MEET EXHAUST GAS REGULATIONS- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-41
PRECAUTIONS FOR DEF - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-42
DEF STORAGE PRECAUTIONS- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-43
PRECAUTIONS WHEN YOU HANDLE HYDRAULIC EQUIPMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-44
PRECAUTIONS WHEN YOU DISCONNECT AND CONNECT PIPES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-46
PRECAUTIONS WHEN YOU HANDLE ELECTRICAL EQUIPMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-52
PRECAUTIONS WHEN YOU HANDLE FUEL SYSTEM EQUIPMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-54
PRECAUTIONS WHEN YOU HANDLE INTAKE SYSTEM EQUIPMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-55
PRACTICAL USEAGE OF KOMTRAX - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-56
DISCONNECT AND CONNECT PUSH PULL TYPE QUICK DISCONNECT - - - - - - - - - - - - - - - - - - - - - - - - - 00-57
PRECAUTIONS FOR DISCONNECT AND CONNECT OF CONNECTORS - - - - - - - - - - - - - - - - - - - - - - - - - 00-61
PROCEDURE TO DISCONNECT AND CONNECT DEUTSCH CONNECTOR - - - - - - - - - - - - - - - - - - - - - - - 00-65
PROCEDURE TO DISCONNECT AND CONNECT SLIDE LOCK CONNECTOR- - - - - - - - - - - - - - - - - - - - - - 00-66
PROCEDURE TO DISCONNECT AND CONNECT PULL TO LOCK TYPE CONNECTOR - - - - - - - - - - - - - - - 00-68
PROCEDURE TO DISCONNECT AND CONNECT PUSH TO LOCK TYPE CONNECTOR - - - - - - - - - - - - - - 00-69
PROCEDURE TO DISCONNECT AND CONNECT TWIST TYPE CONNECTORS - - - - - - - - - - - - - - - - - - - - 00-71
HOW TO READ ELECTRICAL WIRE CODES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-72
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-76
STANDARD VAULE TIGHTEN TABLE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-78
CONVERSION TABLE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-85
01 SPECIFICATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-1
ABBREVIATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-3
SPECIFICATIONS- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-8
DIAGRAM SPECIFICATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-8
SPECIFICATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-12
WEIGHT TABLE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-22
FUEL, COOLANT, AND LUBRICATING OIL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-24
10 STRUCTURE AND FUNCTION- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-1
ABBREVIATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-7
BOOT UP SYSTEM- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-12
BOOT UP SYSTEM DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-12
BOOT UP SYSTEM DIAGRAM (For machines equipped with emergency engine stop switch) - - - - - - - - - - - - 10-13
SYSTEM IN OPERATION LAMP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-15
BATTERY DISCONNECT SWITCH - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-16
ENGINE SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-20
ENGINE SYSTEM DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-20
ENGINE CONTROL SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-22
AUTOMATIC IDLE STOP SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-26
ENGINE COMPONENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-28
COOLING SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-46
COOLING SYSTEM DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-46
00-2 HD465-8, HD605-8

00 INDEX AND FOREWORD INDEX
RADIATOR FAN CONTROL SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-48

COOLING SYSTEM COMPONENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-50
CONTROL SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-64
CONTROL SYSTEM DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-64
RETARDER AND HOIST CONTROL SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-65
MACHINE MONITOR SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-67
REARVIEW MONITOR SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-69
KOMTRAX PLUS SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-70
PAYLOAD METER SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-75
MACHINE LOCK-OUT SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-86
CONTROL SYSTEM COMPONENTS- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-88
HYDRAULIC SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-147
HYDRAULIC SYSTEM DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-147
HYDRAULIC SYSTEM COMPONENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-148
POWER TRAIN SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-168
POWER TRAIN DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-168
TRANSMISSION CONTROL SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-169
GEAR SHIFT CONTROL SYSTEM- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-175
DIRECTION CONTROL SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-177
KOMATSU TRACTION CONTROL SYSTEM (KTCS)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-178
TRAVEL SPEED LIMITATION SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-180
POWER TRAIN COMPONENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-184
WORK EQUIPMENT SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-226
WORK EQUIPMENT CONTROL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-226
HOIST CONTROL- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-227
WORK EQUIPMENT SYSTEM COMPONENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-229
STEERING SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-235
STEERING SYSTEM DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-235
STEERING SYSTEM FUNCTION- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-236
STEERING COLUMN - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-237
STEERING LINKAGE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-238
STEERING SYSTEM COMPONENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-239
BRAKE SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-257
BRAKE SYSTEM DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-257
RETARDER CONTROL- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-259
ARSC SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-260
BRAKE SYSTEM COMPONENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-261
ABS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-282
AUTO-GREASING SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-290
AUTO-GREASING SYSTEM DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-290
FUNCTION OF AUTO-GREASING SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-293
COMPONENT PARTS OF AUTO-GREASING SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-294
UNDERCARRIAGE AND FRAME - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-300
SUSPENSION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-300
FRONT SUSPENSION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-301
REAR SUSPENSION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-303
SUSPENSION CYLINDER- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-305
WORK EQUIPMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-306
STRUCTURE OF WORK EQUIPMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-306
HD465-8, HD605-8 00-3

FUNCTION OF WORK EQUIPMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-306

CAB AND ATTACHMENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-307
ROPS CAB - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-307
CAB MOUNT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-308
20 STANDARD VALUE TABLE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20-1
ABBREVIATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20-3
STANDARD VALUE TABLE FOR ENGINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20-8
STANDARD VALUE TABLE FOR ENGINE: HD465-8 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20-8
STANDARD VALUE TABLE FOR ENGINE: HD605-8 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20-11
STANDARD VALUE TABLE FOR MACHINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20-14
STANDARD VALUE TABLE FOR MACHINE: HD465-8 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20-14
MACHINE SETTING AND PROCEDURE TO MEASURE PERFORMANCE - - - - - - - - - - - - - - - - - - - - - - - - - 20-40
30 TEST AND ADJUST- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-1
ABBREVIATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-6
RELATED INFORMATION TO TEST AND ADJUST- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-11
TOOLS TO TEST AND ADJUST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-11
DIAGRAM FOR TEST AND ADJUST TOOLS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-21
ENGINE AND COOLING SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-22
TEST ENGINE SPEED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-22
TEST BOOST PRESSURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-24
TESTING EXHAUST GAS TEMPERATURE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-28
TEST EXHAUST GAS COLOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-32
TEST AND ADJUST VALVE CLEARANCE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-35
COMPRESSION TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-38
BLOWBY PRESSURE TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-42
TEST ENGINE OIL PRESSURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-44
EGR VALVE AND VGT OIL PRESSURE TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-46
FUEL PRESSURE TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-47
FUEL RETURN RATE AND LEAKAGE TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-49
BLEEDING AIR FROM FUEL SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-53
FUEL CIRCUIT LEAK TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-55
SUPPLY PUMP TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-57
CYLINDER CUT-OUT MODE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-60
NO-INJECTION CRANKING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-61
CLEAN FUEL DOSER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-62
PROGRAM INJECTOR TRIM CODE VALUE TO ENGINE CONTROLLER - - - - - - - - - - - - - - - - - - - - - - - - - - 30-64
PROGRAM ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER - - - - - - - - - - - - - - 30-70
TEST TORQUE CONVERTER STALL SPEED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-71
RADIATOR FAN SPEED TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-73
POWER TRAIN- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-75
TEST POWER TRAIN OIL PRESSURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-75
ADJUST TRANSMISSION INPUT SHAFT SPEED SENSOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-90
ADJUST TRANSMISSION INTERMEDIATE SPEED SENSOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-91
ADJUST TRANSMISSION OUTPUT SPEED SENSOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-92
CHECK AFTER ADJUSTMENT OF TRANSMISSION SPEED SENSORS - - - - - - - - - - - - - - - - - - - - - - - - - - 30-93
MOVE A MACHINE WITH ELECTRICAL SYSTEM PROBLEMS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-94
STEERING SYSTEM- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-99
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-99
TEST SUPPLY PRESSURE OF ORBITROL VALVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-102
00-4 HD465-8, HD605-8

TEST STEERING CYLINDER PRESSURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-104

BLEED AIR FROM STEERING CYLINDER CIRCUIT- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-106
BRAKE SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-107
RELEASE PRESSURE IN BRAKE ACCUMULATOR CIRCUIT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-107
TEST WHEEL BRAKE OIL PRESSURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-108
TEST AND ADJUST BRAKE ACCUMULATOR PRESSURE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-112
TEST NITROGEN GAS PRESSURE IN BRAKE ACCUMULATOR AND CHARGE NITROGEN GAS - - - - - - - 30-115
TEST BRAKE PERFORMANCE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-131
BLEED AIR FROM BRAKE CIRCUIT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-134
TEST PARKING BRAKE OIL PRESSURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-146
RELEASE PARKING BRAKE MANUALLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-147
TEST THE AMOUNT OF FRONT BRAKE PAD WEAR- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-148
TEST THE QUANTITY OF REAR BRAKE DISC WEAR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-149
TEST AND ADJUST HOIST CIRCUIT OIL PRESSURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-150
TEST HOIST CYLINDER SUPPLY PRESSURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-152
TEST OIL PRESSURE OF HOIST EPC VALVE CIRCUIT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-154
TEST RADIATOR FAN CIRCUIT OIL PRESSURE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-156
TEST AND ADJUST FRONT SUSPENSION CYLINDER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-158
TEST AND ADJUST FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION) - - - 30-163
TEST AND ADJUST REAR SUSPENSION CYLINDER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-165
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 AND ITS ATTACHMENTS- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-182
PROCEDURE FOR STARTING UP KOMTRAX TERMINAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-324
DEFAULT SETTING OF KOMTRAX Plus CONTROLLER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-329
SETTING DEFAULT OF WIRELESS LAN MODEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-331
DOWNLOAD KOMTRAX Plus CONTROLLER DATA - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-333
ADJUST WHEN KOMTRAX Plus CONTROLLER IS REPLACED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-337
ADJUST WHEN WIRELESS LAN MODEM IS REPLACED- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-340
ADJUST REARVIEW CAMERA ANGLE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-342
ADJUST OPTICAL AXIS OF HEAD LAMP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-343
ENGINE CONTROLLER VOLTAGE CIRCUIT WORK - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-346
BATTERY DISCONNECT SWITCH WORK - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-347
TEST DIODES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-348
Pm CLINIC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-349
Pm CLINIC SERVICE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-349
PERFORMING QUICK Pm - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-364
40 TROUBLESHOOTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1
ABBREVIATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-16
RELATED INFORMATION ON TROUBLESHOOTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-21
GENERAL TROUBLESHOOTING POINTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-21
HD465-8, HD605-8 00-5

TROUBLESHOOTING POINTS FOR AFTERTREATMENT SYSTEMS- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-22

SEQUENCE OF EVENTS IN TROUBLESHOOTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-28
CHECKS BEFORE TROUBLESHOOTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-30
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-33
TESTING IN ACCORDANCE WITH TESTING PROCEDURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-34
ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-53
PROCEDURE FOR TESTING AND TROUBLESHOOTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-64
SYMPTOM AND TROUBLESHOOTING NUMBERS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-66
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-70
CONNECTORS LIST AND LAYOUT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-73
CONNECTOR CONTACT IDENTIFICATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-101
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-141
FUSE LOCATION TABLE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-147
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) - - - - - - - - - - - - - - - - - - - - - 40-153
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-157
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT - - - - - - - - - - 40-159
PREPARATION OF SHORT SOCKET ADAPTER (FOR FAILURE CODES [CA1883], [CB1883], [CA3135], AND
[CB3135]) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-165
FAILURE CODES TABLE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-167
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-192
FAILURE CODE [1500L0] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-192
FAILURE CODE [15B0NX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-193
FAILURE CODE [15F0KM] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-195
FAILURE CODE [15F0MB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-196
FAILURE CODE [15F7KM] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-197
FAILURE CODE [15G0MW] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-198
FAILURE CODE [15G7KM] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-199
FAILURE CODE [15H0MW] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-200
FAILURE CODE [15J0MW] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-201
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] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-214
FAILURE CODE [15SCMA]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-217
FAILURE CODE [15SDL1] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-218
FAILURE CODE [15SDMA]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-221
FAILURE CODE [15SEL1] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-222
FAILURE CODE [15SEMA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-225
FAILURE CODE [15SFL1] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-226
FAILURE CODE [15SFMA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-229
FAILURE CODE [15SGL1] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-230
FAILURE CODE [15SGMA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-233
FAILURE CODE [15SHL1] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-234
FAILURE CODE [15SHMA]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-237
FAILURE CODE [15SJMA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-238
FAILURE CODE [2C4MNX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-239
FAILURE CODE [2F00KM] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-240
00-6 HD465-8, HD605-8

FAILURE CODE [2G42ZG] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-243

FAILURE CODE [2G43ZG] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-244
FAILURE CODE [6014NX]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-245
FAILURE CODE [879AKA]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-246
FAILURE CODE [879AKB]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-247
FAILURE CODE [879BKA]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-248
FAILURE CODE [879BKB]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-249
FAILURE CODE [879CKA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-251
FAILURE CODE [879CKB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-252
FAILURE CODE [879EMC] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-253
FAILURE CODE [879FMC] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-254
FAILURE CODE [879GKX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-255
FAILURE CODE [989D00] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-256
FAILURE CODE [989L00] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-257
FAILURE CODE [989M00]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-258
FAILURE CODE [989N00] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-259
FAILURE CODE [989X00] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-260
FAILURE CODE [989Y00] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-261
FAILURE CODE [A1U0N3] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-262
FAILURE CODE [A1U0N4] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-263
FAILURE CODE [AA10NX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-265
FAILURE CODE [AB00KE] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-267
FAILURE CODE [AB00KY] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-269
FAILURE CODE [AQ00N3] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-270
FAILURE CODE [AQ00N4] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-271
FAILURE CODE [AQ10N3] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-272
FAILURE CODE [B@BAZG] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-273
FAILURE CODE [B@BAZK]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-274
FAILURE CODE [B@BCNS] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-275
FAILURE CODE [B@BCQA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-276
FAILURE CODE [B@BCZK] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-278
FAILURE CODE [B@C7NS] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-280
FAILURE CODE [B@CENS] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-282
FAILURE CODE [B@JANS]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-283
FAILURE CODE [CA115]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-284
FAILURE CODE [CA122]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-288
FAILURE CODE [CA123]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-290
FAILURE CODE [CA131]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-292
FAILURE CODE [CA132]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-294
FAILURE CODE [CA135]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-296
FAILURE CODE [CA141]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-298
FAILURE CODE [CA144]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-300
FAILURE CODE [CA145]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-302
FAILURE CODE [CA153]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-304
FAILURE CODE [CA154]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-306
FAILURE CODE [CA187]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-308
FAILURE CODE [CA212]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-310
FAILURE CODE [CA213]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-312
FAILURE CODE [CA221]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-314
FAILURE CODE [CA222]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-316
HD465-8, HD605-8 00-7

FAILURE CODE [CA227] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-318

FAILURE CODE [CA234] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-320
FAILURE CODE [CA238] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-321
FAILURE CODE [CA239] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-322
FAILURE CODE [CA271] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-323
FAILURE CODE [CA272] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-325
FAILURE CODE [CA273] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-326
FAILURE CODE [CA274] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-328
FAILURE CODE [CA322] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-329
FAILURE CODE [CA323] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-331
FAILURE CODE [CA324] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-333
FAILURE CODE [CA325] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-335
FAILURE CODE [CA331] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-337
FAILURE CODE [CA332] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-339
FAILURE CODE [CA343] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-341
FAILURE CODE [CA351] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-344
FAILURE CODE [CA352] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-347
FAILURE CODE [CA356] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-349
FAILURE CODE [CA357] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-351
FAILURE CODE [CA386] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-353
FAILURE CODE [CA431] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-355
FAILURE CODE [CA432] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-358
FAILURE CODE [CA441] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-361
FAILURE CODE [CA442] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-364
FAILURE CODE [CA449] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-367
FAILURE CODE [CA451] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-368
FAILURE CODE [CA452] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-370
FAILURE CODE [CA515] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-372
FAILURE CODE [CA516] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-374
FAILURE CODE [CA553] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-376
FAILURE CODE [CA555] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-377
FAILURE CODE [CA556] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-379
FAILURE CODE [CA559] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-381
FAILURE CODE [CA595] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-386
FAILURE CODE [CA687] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-388
FAILURE CODE [CA689] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-390
FAILURE CODE [CA691] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-392
FAILURE CODE [CA692] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-394
FAILURE CODE [CA697] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-396
FAILURE CODE [CA698] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-397
FAILURE CODE [CA731] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-398
FAILURE CODE [CA778] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-401
FAILURE CODE [CA1117] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-403
FAILURE CODE [CA1135] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-406
FAILURE CODE [CA1257] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-409
FAILURE CODE [CA1664] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-410
FAILURE CODE [CA1691] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-412
FAILURE CODE [CA1695] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-414
FAILURE CODE [CA1696] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-416
FAILURE CODE [CA1843] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-418
00-8 HD465-8, HD605-8

FAILURE CODE [CA1844]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-420

FAILURE CODE [CA1879]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-422
FAILURE CODE [CA1881]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-424
FAILURE CODE [CA1883]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-426
FAILURE CODE [CA1921]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-429
FAILURE CODE [CA1922]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-431
FAILURE CODE [CA1923]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-434
FAILURE CODE [CA1924]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-436
FAILURE CODE [CA1925]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-438
FAILURE CODE [CA1927]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-440
FAILURE CODE [CA1928]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-442
FAILURE CODE [CA1942]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-444
FAILURE CODE [CA1963]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-446
FAILURE CODE [CA1977]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-450
FAILURE CODE [CA1993]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-452
FAILURE CODE [CA2185]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-454
FAILURE CODE [CA2186]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-456
FAILURE CODE [CA2249]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-458
FAILURE CODE [CA2265]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-463
FAILURE CODE [CA2266]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-465
FAILURE CODE [CA2271]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-467
FAILURE CODE [CA2272]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-469
FAILURE CODE [CA2349]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-471
FAILURE CODE [CA2353]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-473
FAILURE CODE [CA2357]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-475
FAILURE CODE [CA2381]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-477
FAILURE CODE [CA2382]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-479
FAILURE CODE [CA2383]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-481
FAILURE CODE [CA2386]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-483
FAILURE CODE [CA2387]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-485
FAILURE CODE [CA2555]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-487
FAILURE CODE [CA2556]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-489
FAILURE CODE [CA2637]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-491
FAILURE CODE [CA2639]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-493
FAILURE CODE [CA2732]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-495
FAILURE CODE [CA2733]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-497
FAILURE CODE [CA2741]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-499
FAILURE CODE [CA2765]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-500
FAILURE CODE [CA2777]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-501
FAILURE CODE [CA2878]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-502
FAILURE CODE [CA2881]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-504
FAILURE CODE [CA3133]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-507
FAILURE CODE [CA3134]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-509
FAILURE CODE [CA3135]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-511
FAILURE CODE [CA3167]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-514
FAILURE CODE [CA3251]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-516
FAILURE CODE [CA3253]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-518
FAILURE CODE [CA3254]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-521
FAILURE CODE [CA3255]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-523
FAILURE CODE [CA3256]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-525
HD465-8, HD605-8 00-9

FAILURE CODE [CA3311] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-527

FAILURE CODE [CA3312] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-529
FAILURE CODE [CA3313] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-531
FAILURE CODE [CA3314] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-532
FAILURE CODE [CA3315] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-533
FAILURE CODE [CA3316] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-536
FAILURE CODE [CA3317] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-537
FAILURE CODE [CA3318] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-538
FAILURE CODE [CA3319] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-541
FAILURE CODE [CA3321] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-542
FAILURE CODE [CA3322] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-543
FAILURE CODE [CA3419] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-546
FAILURE CODE [CA3421] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-548
FAILURE CODE [CA4151] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-550
FAILURE CODE [CA4158] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-553
FAILURE CODE [CA4161] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-555
FAILURE CODE [CA4162] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-557
FAILURE CODE [CA4163] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-559
FAILURE CODE [CA4259] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-561
FAILURE CODE [CA4952] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-563
FAILURE CODE [CA5383] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-566
FAILURE CODE [CB115] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-567
FAILURE CODE [CB187] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-571
FAILURE CODE [CB227] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-572
FAILURE CODE [CB238] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-573
FAILURE CODE [CB239] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-575
FAILURE CODE [CB271] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-576
FAILURE CODE [CB272] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-578
FAILURE CODE [CB273] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-579
FAILURE CODE [CB274] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-581
FAILURE CODE [CB343] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-582
FAILURE CODE [CB352] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-585
FAILURE CODE [CB386] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-587
FAILURE CODE [CB441] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-589
FAILURE CODE [CB442] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-592
FAILURE CODE [CB689] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-595
FAILURE CODE [CB697] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-597
FAILURE CODE [CB698] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-598
FAILURE CODE [CB731] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-599
FAILURE CODE [CB778] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-602
FAILURE CODE [CB1117] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-604
FAILURE CODE [CB1257] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-607
FAILURE CODE [CB1664] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-608
FAILURE CODE [CB1691] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-610
FAILURE CODE [CB1695] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-612
FAILURE CODE [CB1696] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-614
FAILURE CODE [CB1879] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-616
FAILURE CODE [CB1881] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-618
FAILURE CODE [CB1883] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-620
FAILURE CODE [CB1921] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-623
00-10 HD465-8, HD605-8

FAILURE CODE [CB1922]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-625

FAILURE CODE [CB1923]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-628
FAILURE CODE [CB1924]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-630
FAILURE CODE [CB1925]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-632
FAILURE CODE [CB1927]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-634
FAILURE CODE [CB1928]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-636
FAILURE CODE [CB1963]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-638
FAILURE CODE [CB1977]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-642
FAILURE CODE [CB1993]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-644
FAILURE CODE [CB2265]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-646
FAILURE CODE [CB2266]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-648
FAILURE CODE [CB2637]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-650
FAILURE CODE [CB2639]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-652
FAILURE CODE [CB2732]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-654
FAILURE CODE [CB2733]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-656
FAILURE CODE [CB2741]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-658
FAILURE CODE [CB2777]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-659
FAILURE CODE [CB2878]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-660
FAILURE CODE [CB2881]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-662
FAILURE CODE [CB3133]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-665
FAILURE CODE [CB3134]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-667
FAILURE CODE [CB3135]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-669
FAILURE CODE [CB3167]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-672
FAILURE CODE [CB3251]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-674
FAILURE CODE [CB3253]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-676
FAILURE CODE [CB3254]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-679
FAILURE CODE [CB3255]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-681
FAILURE CODE [CB3256]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-683
FAILURE CODE [CB3311]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-685
FAILURE CODE [CB3312]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-687
FAILURE CODE [CB3313]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-689
FAILURE CODE [CB3314]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-690
FAILURE CODE [CB3315]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-691
FAILURE CODE [CB3316]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-694
FAILURE CODE [CB3317]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-695
FAILURE CODE [CB3318]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-696
FAILURE CODE [CB3319]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-699
FAILURE CODE [CB3321]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-700
FAILURE CODE [CB3322]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-701
FAILURE CODE [CB4151]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-704
FAILURE CODE [CB4158]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-707
FAILURE CODE [CB4161]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-708
FAILURE CODE [CB4162]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-710
FAILURE CODE [CB4163]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-712
FAILURE CODE [CB4259]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-714
FAILURE CODE [CB4952]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-716
FAILURE CODE [CB5383]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-719
FAILURE CODE [D150KB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-720
FAILURE CODE [D150KZ]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-721
FAILURE CODE [D164KY] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-722
HD465-8, HD605-8 00-11

FAILURE CODE [D19HKZ] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-723

FAILURE CODE [D19JKZ] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-725
FAILURE CODE [D19QKZ] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-726
FAILURE CODE [D1EHKA]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-728
FAILURE CODE [D1EHKB]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-730
FAILURE CODE [D1EHKY]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-732
FAILURE CODE [D1EMKA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-733
FAILURE CODE [D1EMKB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-734
FAILURE CODE [D1EMKY] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-735
FAILURE CODE [D1FBKB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-736
FAILURE CODE [D5ZHL6] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-738
FAILURE CODE [D5ZKKZ] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-740
FAILURE CODE [D862KA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-742
FAILURE CODE [DAF0KT] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-743
FAILURE CODE [DAF0MB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-744
FAILURE CODE [DAF0MC] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-745
FAILURE CODE [DAF3KK] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-746
FAILURE CODE [DAF8KB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-748
FAILURE CODE [DAFDKB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-749
FAILURE CODE [DAFGMC] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-751
FAILURE CODE [DAFLKA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-752
FAILURE CODE [DAFLKB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-755
FAILURE CODE [DAFQKR] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-758
FAILURE CODE [DAQ0KK] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-759
FAILURE CODE [DAQ0KT]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-762
FAILURE CODE [DAQ0MC] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-763
FAILURE CODE [DAQ1KA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-764
FAILURE CODE [DAQ9KQ] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-770
FAILURE CODE [DAQLKA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-771
FAILURE CODE [DAQLKB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-774
FAILURE CODE [DAQQKR] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-777
FAILURE CODE [DAQRKR] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-778
FAILURE CODE [DAQRMA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-779
FAILURE CODE [DAQV00] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-780
FAILURE CODE [DAQW00] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-781
FAILURE CODE [DAZ9KQ]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-782
FAILURE CODE [DAZQKR] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-783
FAILURE CODE [DB10KT] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-784
FAILURE CODE [DB10MC] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-785
FAILURE CODE [DB11KA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-786
FAILURE CODE [DB11KA] (For machines equipped with emergency engine stop switch) - - - - - - - - - - - - - - 40-789
FAILURE CODE [DB12KK] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-792
FAILURE CODE [DB13KK] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-795
FAILURE CODE [DB19KQ] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-798
FAILURE CODE [DB1LKA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-799
FAILURE CODE [DB1LKB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-802
FAILURE CODE [DB1QKR] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-805
FAILURE CODE [DB1QMA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-806
FAILURE CODE [DB1RKR] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-807
00-12 HD465-8, HD605-8

FAILURE CODE [DB2QKR] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-808

FAILURE CODE [DB2QKR] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-814
FAILURE CODE [DB2RKR] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-821
FAILURE CODE [DB2RKR] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-827
FAILURE CODE [DBC0KT] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-834
FAILURE CODE [DBC0MC]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-835
FAILURE CODE [DBC1KA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-836
FAILURE CODE [DBC2KK] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-839
FAILURE CODE [DBC3KK] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-841
FAILURE CODE [DBC9KQ] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-844
FAILURE CODE [DBCLKA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-845
FAILURE CODE [DBCLKB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-847
FAILURE CODE [DBCQKR]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-849
FAILURE CODE [DBCQMA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-850
FAILURE CODE [DBCRKR]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-851
FAILURE CODE [DBV0MC] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-852
FAILURE CODE [DBV1KK] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-853
FAILURE CODE [DBV6KB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-855
FAILURE CODE [DBV7KB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-857
FAILURE CODE [DBVLKA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-858
FAILURE CODE [DBVLKB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-861
FAILURE CODE [DBVQKR]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-864
FAILURE CODE [DBVRKR] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-865
FAILURE CODE [DBVVKR] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-866
FAILURE CODE [DBVWKR] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-867
FAILURE CODE [DDAAL6] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-868
FAILURE CODE [DDAAL6] (For machines equipped with emergency engine stop switch) - - - - - - - - - - - - - - - 40-870
FAILURE CODE [DDACL4] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-873
FAILURE CODE [DDADKA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-875
FAILURE CODE [DDADKY] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-877
FAILURE CODE [DDD7KX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-878
FAILURE CODE [DDP6L4] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-880
FAILURE CODE [DDTHKA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-882
FAILURE CODE [DDTJKA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-884
FAILURE CODE [DDTKKA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-886
FAILURE CODE [DDTLKA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-888
FAILURE CODE [DDTMKA]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-890
FAILURE CODE [DDTNKA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-892
FAILURE CODE [DDTPKA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-894
FAILURE CODE [DF10KA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-896
FAILURE CODE [DF10KB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-900
FAILURE CODE [DGE5KX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-905
FAILURE CODE [DGF1KX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-907
FAILURE CODE [DGR2KB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-909
FAILURE CODE [DGR6KB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-911
FAILURE CODE [DGR6L8] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-912
FAILURE CODE [DGT1KX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-914
FAILURE CODE [DGT4KA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-916
FAILURE CODE [DGT4KB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-918
FAILURE CODE [DGT4KY] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-920
HD465-8, HD605-8 00-13

FAILURE CODE [DHA4KA]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-922

FAILURE CODE [DHAAMA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-924
FAILURE CODE [DHABMA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-925
FAILURE CODE [DHACMA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-926
FAILURE CODE [DHADMA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-927
FAILURE CODE [DHP4KY]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-928
FAILURE CODE [DHP4KZ] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-930
FAILURE CODE [DHP6KA]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-936
FAILURE CODE [DHP6KX]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-938
FAILURE CODE [DHP7KA]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-944
FAILURE CODE [DHP7KX]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-946
FAILURE CODE [DHQ2KX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-952
FAILURE CODE [DHT5KX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-956
FAILURE CODE [DHT5L6] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-958
FAILURE CODE [DHT8ZG]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-962
FAILURE CODE [DHU2KX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-963
FAILURE CODE [DHUCKX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-975
FAILURE CODE [DHUDKX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-978
FAILURE CODE [DHUHKX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-980
FAILURE CODE [DHULKX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-982
FAILURE CODE [DHUMKX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-984
FAILURE CODE [DHUPKX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-986
FAILURE CODE [DHUTKX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-988
FAILURE CODE [DHY9KX]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-990
FAILURE CODE [DJF1KA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-992
FAILURE CODE [DK30KX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-994
FAILURE CODE [DK51L5] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-996
FAILURE CODE [DK53L8] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1001
FAILURE CODE [DKD0L6] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1007
FAILURE CODE [DKH0KX]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1009
FAILURE CODE [DKH1KX]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1011
FAILURE CODE [DLF1KA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1013
FAILURE CODE [DLF1LC] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1014
FAILURE CODE [DLF2KA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1016
00-14 HD465-8, HD605-8

FAILURE CODE [DLF2LC] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1017

FAILURE CODE [DLF6KA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1019
FAILURE CODE [DLF6L3] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1020
FAILURE CODE [DLF8MA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1029
FAILURE CODE [DLM3KA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1035
FAILURE CODE [DLM3LC] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1036
FAILURE CODE [DLM3MB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1038
FAILURE CODE [DLT3KA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1039
FAILURE CODE [DLT3LC] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1040
FAILURE CODE [DPQ1KR] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1042
FAILURE CODE [DSJ0KR] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1052
FAILURE CODE [DV00KB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1053
FAILURE CODE [DW2AKA]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1055
FAILURE CODE [DW2AKB]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1056
FAILURE CODE [DW2AKY]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1057
FAILURE CODE [DW2AL1] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1058
FAILURE CODE [DW2ALH] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1059
FAILURE CODE [DW2BKA]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1060
FAILURE CODE [DW2BKB]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1061
FAILURE CODE [DW2BKY]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1062
FAILURE CODE [DW2BL1] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1063
FAILURE CODE [DW2BLH] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1064
FAILURE CODE [DW35KZ] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1065
FAILURE CODE [DW4BK4] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1069
FAILURE CODE [DW4BMA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1073
FAILURE CODE [DW73KA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1079
FAILURE CODE [DW73KB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1081
FAILURE CODE [DW73KY] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1083
FAILURE CODE [DW7BKB]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1086
FAILURE CODE [DW7BKY]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1087
FAILURE CODE [DW7BKZ] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1088
FAILURE CODE [DW7NKZ]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1089
FAILURE CODE [DWD6KA]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1091
FAILURE CODE [DWD6KB]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1092
FAILURE CODE [DWD6KY]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1094
FAILURE CODE [DWD6MA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1095
HD465-8, HD605-8 00-15

FAILURE CODE [DWD7K4] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1096

FAILURE CODE [DWD7KA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1097
FAILURE CODE [DWD7KB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1098
FAILURE CODE [DWD7KY] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1100
FAILURE CODE [DWD7MA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1101
FAILURE CODE [DWNDKZ] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1102
FAILURE CODE [DWNDMA]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1104
FAILURE CODE [DWNEKZ] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1106
FAILURE CODE [DWNEMA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1108
FAILURE CODE [DWNMKZ] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1110
FAILURE CODE [DX11K4] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1112
FAILURE CODE [DX11KA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1114
FAILURE CODE [DX11KB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1116
FAILURE CODE [DX11KY] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1118
FAILURE CODE [DX11MA]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1119
FAILURE CODE [DX37K4] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1156
FAILURE CODE [DX38K4] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1165
FAILURE CODE [DXH1KA]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1174
00-16 HD465-8, HD605-8

FAILURE CODE [DXH1KB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1176

FAILURE CODE [DXH1KY] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1178
FAILURE CODE [DXH2KA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1179
FAILURE CODE [DXHHKA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1220
FAILURE CODE [DXHHKB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1222
FAILURE CODE [DXHHKY] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1224
FAILURE CODE [DY30MA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1226
FAILURE CODE [DY30MC] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1228
FAILURE CODE [DY30ME] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1231
FAILURE CODE [F@BYNR] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1233
FAILURE CODE [F@BYNS] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1234
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1235
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1235
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1243
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1246
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP- - - - - - - - - - - - 40-1248
E-5 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING - - - - 40-1250
E-6 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING (For machines
equipped with emergency engine stop switch) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1253
E-7 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1256
E-8 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS)
40-1258
E-9 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1260
E-10 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1262
E-11 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL - - - - - - - - - - - - 40-1265
E-12 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1269
E-13 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES
NOT OPERATE PROPERLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1272
E-14 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION- - 40-1274
E-15 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL - - - - - - - - - - - - - - - - - - - - - - - - 40-1276
E-16 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROP-
ERLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1278
E-17 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS - - - - - - - - - - - - - - - - - - - 40-1279
HD465-8, HD605-8 00-17

E-18 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY- - - - - - - - - - - - - - - - - - - - - - - - - - 40-1283

E-19 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED- - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1287
E-20 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL - - - - - - - - - - - - - - - - - - - - - - - - - 40-1290
E-21 REARVIEW MONITOR DOES NOT DISPLAY IMAGES WHILE REVERSE LINKED DISPLAY FUNCTION IS
ENABLED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1292
E-22 GUIDE LINE ON REARVIEW MONITOR IS NOT DISPLAYED WHILE GUIDE LINE IS SET- - - - - - - - - 40-1295
E-23 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1297
E-24 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1299
E-25 MACHINE MONITOR CANNOT BE OPERATED WHEN STARTING SWITCH IS IN OFF POSITION - - 40-1301
E-26 ALARM BUZZER DOES NOT SOUND - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1302
E-27 ALARM BUZZER DOES NOT STOP SOUNDING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1304
E-28 AISS FUNCTION DOES NOT OPERATE PROPERLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1306
E-29 HOIST LEVER DOES NOT OPERATE PROPERLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1308
E-30 FUEL FEED PUMP DOES NOT OPERATE OR DOES NOT STOP AUTOMATICALLY - - - - - - - - - - - - 40-1310
E-31 TURN SIGNAL LAMP AND WINKER LAMP (HAZARD LAMP) DO NOT OPERATE PROPERLY - - - - - 40-1313
E-32 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS - - - - - - - - - - - - - - - - - - - - - - 40-1317
E-33 SMALL LAMP (CLEARANCE LAMP) DOES NOT LIGHT UP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1320
E-34 TAIL LAMP DOES NOT LIGHT UP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1323
E-35 (LOW BEAM) HEAD LAMP DOES NOT LIGHT UP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1326
E-36 (HIGH BEAM) HEAD LAMP DOES NOT LIGHT UP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1328
E-37 NEITHER (LOW BEAM) NOR (HIGH BEAM) HEAD LAMPS LIGHTS UP - - - - - - - - - - - - - - - - - - - - - - 40-1330
E-38 HIGH BEAMS DO NOT LIGHT UP WHILE PASSING SWITCH IS OPERATED - - - - - - - - - - - - - - - - - - 40-1332
E-39 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1334
E-40 DATA DOWNLOADING BY USING WIRELESS LAN CAN NOT BE PERFORMED - - - - - - - - - - - - - - - 40-1336
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) - - - - - - - - - - - - - - - - - - - 40-1337
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) - - - - - - - - - - - - - - - - - - - - - - - - 40-1337
FAILURE MODE AND CAUSE TABLE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1338
H-1 MACHINE DOES NOT START - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1347
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE HUNTS) - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1350
H-3 LOCKUP IS NOT RELEASED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1351
H-4 ABNORMALLY LARGE SHOCKS RESULT FROM STARTING OF MACHINE AND GEAR SHIFTING - - 40-1352
H-5 GEAR IS NOT SHIFTED UP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1354
H-6 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN LOCKUP DRIVE MODE AT ALL GEAR
SPEEDS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1357
H-7 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN TORQUE CONVERTER DRIVE MODE
40-1358
H-8 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING AT SOME GEAR SPEED- - - - - - 40-1359
H-9 LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED - - - - - - - - - - - 40-1361
H-10 OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1364
H-11 OIL PRESSURE OF TORQUE CONVERTER IS LOW - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1365
H-12 STEERING WHEEL IS HEAVY TO OPERATE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1366
H-13 STEERING WHEEL CANNOT BE OPERATED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1367
H-14 STEERING WHEEL WAGGLES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1368
H-15 FRONT BRAKE DOES NOT WORK ENOUGH - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1369
H-16 REAR BRAKE DOES NOT WORK ENOUGH - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1370
H-17 DUMP BODY RISING SPEED IS LOW - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1372
H-18 HYDRAULIC DRIFT OF DUMP BODY IS LARGE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1374
H-19 DUMP BODY DOES NOT MOVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1375
H-20 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) - - - - - - - - - - - - - - - - - - - - - - - 40-1377
H-21 UNUSUAL NOISE IS HEARD FROM AROUND FAN - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1378
00-18 HD465-8, HD605-8

TROUBLESHOOTING OF ENGINE (S-MODE)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1379

INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)- - - - - - - - - - - - - - - - - - - - - - - - 40-1379
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION - - - - - - 40-1380
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1381
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT
START) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1382
S-4 ENGINE STARTABILITY IS POOR- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1383
S-5 ENGINE DOES NOT PICK UP SMOOTHLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1385
S-6 ENGINE STOPS DURING OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1387
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1389
S-8 ENGINE LACKS POWER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1390
S-9 KDPF GETS CLOGGED IN A SHORT TIME - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1392
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1394
S-11 OIL BECOMES CONTAMINATED QUICKLY- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1395
S-12 FUEL CONSUMPTION IS EXCESSIVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1396
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) - - - - - - - 40-1397
S-14 OIL PRESSURE DROPS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1398
S-15 FUEL MIXES INTO ENGINE OIL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1399
S-16 WATER MIXES INTO ENGINE OIL (MILKY) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1400
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1401
S-18 UNUSUAL NOISE IS HEARD- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1402
S-19 VIBRATION IS EXCESSIVE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1403
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1404
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1405
S-22 ACTIVE REGENERATION TAKES TIME - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1406
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION - - - - - - - - - - - - - - - - - - - - - - - 40-1407
50 DISASSEMBLY AND ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-1
ABBREVIATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-6
DISASSEMBLE AND ASSEMBLE-RELATED INFORMATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-11
HOW TO READ THIS MANUAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-11
COATING MATERIALS LIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-13
SPECIAL TOOL LIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-16
DIAGRAMS OF SPECIAL TOOLS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-28
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-33
REMOVE AND INSTALL INJECTOR ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-57
REMOVE AND INSTALL FUEL DOSER ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-106
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-110
REMOVE AND INSTALL EGR VALVE ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-207
REMOVE AND INSTALL EGR COOLER ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-213
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-229
REMOVE AND INSTALL ALTERNATOR BELT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-231
REMOVE AND INSTALL COOLER ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-234
REMOVE AND INSTALL RADIATOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-262
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - 50-275
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-280
REMOVE AND INSTALL ENGINE ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-293
REMOVE AND INSTALL ENGINE FRONT OIL SEAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-320
REMOVE AND INSTALL ENGINE REAR OIL SEAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-324
REMOVE AND INSTALL OUTPUT SHAFT ASSEMBLY- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-330
HD465-8, HD605-8 00-19

DISASSEMBLE AND ASSEMBLE OF OUTPUT SHAFT ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-335

REMOVE AND INSTALL KDPF ASSEMBLY (WITH BRACKET) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-338
REMOVE AND INSTALL KDPF ASSEMBLY (WITHOUT BRACKET) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-347
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-361
REMOVE AND INSTALL KCCV ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-375
REMOVE AND INSTALL AIR CLEANER ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-379
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - 50-383
POWER TRAIN- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-386
REMOVE AND INSTALL TORQUE CONVERTER AND TRANSMISSION ASSEMBLY - - - - - - - - - - - - - - - - 50-386
DISCONNECT AND CONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY - - - - - - - - - - - 50-394
DISASSEMBLE AND ASSEMBLE OF TORQUE CONVERTER ASSEMBLY- - - - - - - - - - - - - - - - - - - - - - - - 50-414
DISASSEMBLE AND ASSEMBLE OF TRANSMISSION ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-433
REMOVE AND INSTALL DIFFERENTIAL ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-482
DISASSEMBLE AND ASSEMBLE OF DIFFERENTIAL ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-486
REMOVE AND INSTALL FRONT BRAKE CALIPER PAD - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-503
REMOVE AND INSTALL FRONT BRAKE CALIPER ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-504
DISASSEMBLE AND ASSEMBLE OF FRONT BRAKE CALIPER ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - 50-506
REMOVE AND INSTALL FINAL DRIVE AND REAR BRAKE ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - 50-508
REMOVE AND INSTALL FINAL DRIVE, REAR BRAKE AND PARKING BRAKE ASSEMBLY - - - - - - - - - - - 50-516
DISASSEMBLE AND ASSEMBLE OF FINAL DRIVE, REAR BRAKE AND PARKING BRAKE ASSEMBLY - - 50-523
REMOVE AND INSTALL FINAL DRIVE CARRIER ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-539
DISASSEMBLE AND ASSEMBLE OF FINAL DRIVE CARRIER ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - 50-542
STEERING SYSTEM- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-543
DISASSEMBLE AND ASSEMBLE OF STEERING CYLINDER ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - 50-543
REMOVE AND INSTALL FRONT WHEEL ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-548
REMOVE AND INSTALL REAR WHEEL ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-551
REMOVE AND INSTALL FRONT SUSPENSION CYLINDER ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - 50-555
DISASSEMBLE AND ASSEMBLE OF FRONT SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER
RING) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-557
REMOVE AND INSTALL REAR SUSPENSION CYLINDER ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - 50-561
DISASSEMBLE AND ASSEMBLE OF REAR SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER
RING) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-562
DISASSEMBLE AND ASSEMBLE OF FRONT WHEEL HUB ASSEMBLY- - - - - - - - - - - - - - - - - - - - - - - - - - 50-566
HYDRAULIC SYSTEM- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-573
DISASSEMBLE AND ASSEMBLE OF HOIST CYLINDER ASSEMBLY- - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-573
WORK EQUIPMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-583
REMOVE AND INSTALL DUMP BODY ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-583
CAB AND ITS ATTACHMENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-587
REMOVE AND INSTALL AIR CONDITIONER ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-587
REMOVE AND INSTALL OPERATOR'S SEAT ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-601
REMOVE AND INSTALL SEAT BELT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-606
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-608
REMOVE AND INSTALL RETARDER AND HOIST CONTROLLER ASSEMBLY - - - - - - - - - - - - - - - - - - - - - 50-613
REMOVE AND INSTALL ABS CONTROLLER ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-615
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY- - - - - - - - - - - - - - - - - - - - - - - - - - - 50-617
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-619
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-624
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR - - - - - - - - - - - - - - - - - - - - - - - 50-626
00-20 HD465-8, HD605-8

REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-629

REMOVE AND INSTALL KOMTRAX PLUS CONTROLLER ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-632
REMOVE AND INSTALL KOMTRAX CONTROLLER ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-635
REMOVE AND INSTALL WIRELESS LAN UNIT ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-637
60 MAINTENANCE STANDARD- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-1
ABBREVIATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-3
ENGINE AND COOLING SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-8
MAINTENANCE STANDARD FOR ENGINE MOUNT- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-8
MAINTENANCE STANDARD FOR OUTPUT SHAFT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-9
MAINTENANCE STANDARD FOR COOLING FAN PUMP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-11
MAINTENANCE STANDARD FOR SERVO VALVE FOR COOLING FAN PUMP - - - - - - - - - - - - - - - - - - - - - - 60-13
MAINTENANCE STANDARD FOR COOLING FAN MOTOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-14
POWER TRAIN - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-16
MAINTENANCE STANDARD FOR DRIVE SHAFT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-16
MAINTENANCE STANDARD FOR TORQUE CONVERTER AND TRANSMISSION MOUNT - - - - - - - - - - - - - 60-17
MAINTENANCE STANDARD FOR TORQUE CONVERTER AND PTO - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-18
MAINTENANCE STANDARD FOR TORQUE CONVERTER VALVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-22
MAINTENANCE STANDARD FOR TRANSMISSION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-24
MAINTENANCE STANDARD FOR TRANSMISSION CONTROL VALVE- - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-30
MAINTENANCE STANDARD FOR H, L, 4TH, 3RD, R, 2ND, and 1ST ECMV- - - - - - - - - - - - - - - - - - - - - - - - - 60-31
MAINTENANCE STANDARD FOR LOCKUP CLUTCH ECMV - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-32
MAINTENANCE STANDARD FOR FRONT AXLE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-33
MAINTENANCE STANDARD FOR REAR AXLE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-34
MAINTENANCE STANDARD FOR DIFFERENTIAL- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-35
MAINTENANCE STANDARD FOR FINAL DRIVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-36
STEERING SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-37
MAINTENANCE STANDARD FOR STEERING COLUMN - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-37
MAINTENANCE STANDARD FOR STEERING LINKAGE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-38
MAINTENANCE STANDARD FOR DEMAND VALVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-41
MAINTENANCE STANDARD FOR STEERING CYLINDER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-44
BRAKE SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-45
MAINTENANCE STANDARD FOR SLACK ADJUSTER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-45
MAINTENANCE STANDARD FOR FRONT BRAKE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-46
MAINTENANCE STANDARD FOR REAR BRAKE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-47
UNDERCARRIAGE AND FRAME - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-49
MAINTENANCE STANDARD FOR FRONT SUSPENSION CYLINDER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-49
MAINTENANCE STANDARD FOR REAR SUSPENSION CYLINDER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-51
HYDRAULIC SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-53
MAINTENANCE STANDARD FOR STEERING AND HOIST PUMP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-53
MAINTENANCE STANDARD FOR SERVO VALVE FOR STEERING AND HOIST PUMP- - - - - - - - - - - - - - - - 60-54
MAINTENANCE STANDARD FOR POWER TRAIN AND BRAKE COOLING DUPLEX PUMP- - - - - - - - - - - - - 60-56
MAINTENANCE STANDARD FOR BRAKE COOLING, CONTROL TRIPLE PUMP - - - - - - - - - - - - - - - - - - - - 60-57
MAINTENANCE STANDARD FOR HOIST VALVE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-59
WORK EQUIPMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-61
MAINTENANCE STANDARD FOR HOIST CYLINDER- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-61
CAB AND ITS ATTACHMENTS- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-62
MAINTENANCE STANDARD FOR CAB MOUNT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-62
80 THE OTHER INFORMATION- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-1
ABBREVIATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-4
AIR CONDITIONER SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-9
HD465-8, HD605-8 00-21

PRECAUTIONS FOR REFRIGERANT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-9

AIR CONDITIONER COMPONENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-10
SPECIFICATIONS OF AIR CONDITIONER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-12
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-13
OUTLINE OF REFRIGERATION CYCLE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-14
COMPONENT PARTS OF AIR CONDITIONER SYSTEM- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-16
AIR CONDITIONER UNIT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-16
COMPONENT PARTS OF AIR CONDITIONER UNIT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-19
AIR CONDITIONER CONTROLLER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-23
COMPRESSOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-24
CONDENSER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-25
SENSORS FOR AIR CONDITIONER SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-27
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER - - - - - - - 80-28
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER - - - - - - - - - - - - - 80-30
AIR CONDITIONER SYSTEM DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-32
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER- - - - - - - - - - - - - - - - - - - - - - - - - - - 80-33
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS - - - - - 80-35
TESTING AIR LEAKAGE (DUCT) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-38
METHOD FOR TESTING AIR LEAKAGE (DUCT) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-38
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-41
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE
MACHINE MONITOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-42
TEST VENT (MODE) CHANGEOVER- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-44
METHOD FOR TESTING VENT (MODE) CHANGEOVER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-44
TESTING FRESH/RECIRC AIR CHANGEOVER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-45
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-45
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-46
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT - - - - - - - - - - - - - - - - - - - - - - - 80-46
TEST RELAYS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-47
METHOD FOR TESTING RELAYS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-47
AIR CONDITIONER TROUBLESHOOTING CHART 1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-48
AIR CONDITIONER TROUBLESHOOTING CHART 2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-49
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-52
FAILURE CODE [879AKA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-53
FAILURE CODE [879AKB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-54
FAILURE CODE [879BKA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-55
FAILURE CODE [879BKB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-56
FAILURE CODE [879CKA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-58
FAILURE CODE [879CKB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-59
FAILURE CODE [879EMC] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-60
FAILURE CODE [879FMC] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-61
FAILURE CODE [879GKX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-62
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)- - - - - 80-63
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) - - - - - - 80-65
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-68
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-70
TROUBLESHOOTING USING GAUGE PRESSURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-72
CONNECTION OF SERVICE TOOL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-74
METHOD FOR CONNECTING SERVICE TOOL- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-74
00-22 HD465-8, HD605-8

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
ABBREVIATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90-3
HYDRAULIC CIRCUIT DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90-8
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90-8
HYDRAULIC CIRCUIT DIAGRAM (1/3)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90-13
POWER TRAIN HYDRAULIC DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90-19
ELECTRICAL CIRCUIT DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90-21
ELECTRICAL DIAGRAMS SYMBOLS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90-21
INTERNAL CAB ELECTRICAL DIAGRAM (1/10) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90-25
INTERNAL CAB ELECTRICAL DIAGRAM (10/10) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90-43
EXTERNAL CAB ELECTRICAL DIAGRAM (1/8) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90-45
INDEX - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1
HD465-8, HD605-8 00-23

ABBREVIATIONS 00 INDEX AND FOREWORD
ABBREVIATIONS
q These abbreviations include those used in the shop manual for parts, components, and functions which are not easily un-
derstood. The abbreviation is shown and defined in full.
q The list may not include general usage abbreviations.
q Special abbreviations are identified in the text.
q This list of abbreviations is in two parts. One part is abbreviations used in the text of the manual, and the second is abbre-
viations used in the circuit diagram.
List of abbreviations used in the text
Function (major applicable

Abbreviation Terms shown completely machine (*), or component Explanation
and system)
Travel and brake When the tires slide (wheels do not turn), the brakes
ABS Antilock Brake System are released, and when the wheels start to turn, the
(HD, HM) brakes are applied again.
Automatic Idle Setting

AISS Engine This function automatically sets the idle speed.
System
Steering A lever is used to perform the steering operations. It

Advanced Joystick
AJSS shifts gear and changes direction (FORWARD or
Steering System (WA) REVERSE).
Travel and brake When the accelerator pedal is released while the
Automatic Retarder
ARAC machine travels downhill, this function automatically
Accelerator Control (HD, HM) applies the retarder with a constant brake force.
machine travels downhill, this function automatically
Automatic Retarder
ARSC applies the retarder. It ensures that the machine
Speed Control (HD, HM) speed does not accelerate above the speed set by
the operator.
Travel and brake When the tires slip on soft ground surfaces, this
ASR Automatic Spin Regulator function automatically uses the brake force to power
(HD, HM) each wheel.
A device attached onto the standard machine, to let

ATT Attachment Work equipment
it do different operations.
Brake When the retarder is not used, this valve bypasses

Brake Cooling oil control
BCV part of the brake cooling oil to reduce the load on the
Valve (HD) hydraulic pump.
Communication and One of the communication standards that is used in

CAN Controller Area Network
electronic control the circuits on the machine.
Crankcase Depression A valve installed in the KCCV. It is written as CDR

CDR Engine
Regulator valve and it is not used independently.
This system can actuate several actuators at the

Closed-center Load
CLSS Hydraulic system same time regardless of the load (Improves mixed
Sensing System
operations over OLSS).
Engine controller electronically controls supply

CRI Common Rail Injection Engine pump, common rail, and injector. This function
correctly maintains fuel injection quantity and timing.
Electronic control device which uses the signals

from the sensors on the machine. These signals
ECM Electronic Control Module Electronic control system
indicate the actuators to function for the best
operation. (Same as ECU)
00-24 HD465-8, HD605-8

00 INDEX AND FOREWORD ABBREVIATIONS

and system)
Transmission Electromagnetic valve that gradually proportions oil

Electronic Control
ECMV pressure to engage clutches and decrease
Modulation Valve (D, HD, WA, etc) transmission shock.
Travel This system absorbs machine vibration during high

Electronically Controlled
ECSS speed to ensure smooth travel, using hydraulic
Suspension System (WA) spring effect of the accumulator.

ECU Electronic Control Unit Electronic control system
operation. (Same as ECM)
This function recirculates part of exhaust gas back

Exhaust Gas
EGR Engine to the combustion chamber to reduce temperature
Recirculation
and control NOx emissions.
This system allows monitor check of each sensor of

Equipment Management the machine. (Data includes oil and filter
EMMS Machine monitor
Monitoring System replacement intervals, machine malfunctions, failure
codes, and failure records)
Electromagnetic This mechanism allows actuators to be operated in

EPC Hydraulic system
Proportional Control proportion to the current supplied.
This structure protects the operator from objects that

Falling Object Protection fall.
FOPS Cab and canopy
Structure
This performance is standardized as ISO 3449.
F-N-R Forward-Neutral-Reverse Operation Forward - Neutral - Reverse
Communication Global Positioning System: This system uses

Global Positioning
GPS (KOMTRAX, KOMTRAX satellites to determine the machine’s present
System
Plus) location.
Communication Global Navigation Satellite System: This system

Global Navigation
GNSS (KOMTRAX, KOMTRAX uses satellites to determine the present machine
Satellite System
Plus) location.
Steering This function uses the hydraulic motor and bevel

Hydrostatic Steering shaft to control the difference in travel speed of right
HSS
System (D) and left tracks. Therefore the machine can turn
without using steering clutches.
Transmission This function uses the hydraulic pump and motor

Hydro Static
HST together, to shift the speed range without using
Transmission (D, WA) gears.
Information and A generally accepted term for engineered and

Communication and
ICT Communication applied technology of information procedures and
electronic control
Technology communication.
This valve is installed at the inlet port of the pump,

IMA Inlet Metering Actuator Engine and adjusts fuel intake quantity to control fuel
volume of the supply pump. (Same as IMV)
This is a device to detect the angle and speed of the

IMU Inertial Measurement Unit Engine
3 pivot points that control movements.

IMV Inlet Metering Valve Engine and it adjusts fuel intake quantity to control fuel
release volume of supply pump. (Same as IMA)
HD465-8, HD605-8 00-25


and system)
This mechanism causes the separation of oil in

KOMATSU Closed blowby gas and puts it in the intake side to be
KCCV Engine
Crankcase Ventilation burned in the engine. It is primarily made up of
filters.
KOMATSU Catalyzed This filter captures soot in exhaust gas.

KCSF Engine
Soot Filter It is assembled in the KDPF.
This component is used to purify exhaust gas.

KOMATSU Diesel
KDOC Engine It is assembled in to KDPF or assembled with the
Oxidation Catalyst
muffler.
This component is used to purify the exhaust gas.

KDOC (catalyst) and KCSF (filter to capture soot)
KOMATSU Diesel are part of it.
KDPF Engine
Particulate Filter
It is installed in the same location as a standard
muffler.
Travel and brake This function recovers the traction of the wheels by
using the brakes automatically with the necessary
KOMATSU Traction
KTCS force. At the same time, it activates the inter-axle
Control System (HM) differential lock when the wheels idle while the
machine travels on soft ground.
Liquid crystal elements assembled into components

LCD Liquid Crystal Display Machine monitor
such as a monitor.
Refers to a semiconductor element that emits light

LED Light Emitting Diode Electronic parts
when energized in the forward direction.
Local Interconnect Communication and One of the communication standards that is used in
LIN
Network electronic control the circuits on the machine.
Function that senses pressure differences of the

LS Load Sensing Hydraulic system pump and controls output volume corresponding to
load.
Low Voltage Differential Communication and One of the communication standards that is used in
LVDS
Signaling electronic control the circuits on the machine.
This indicates airflow of the engine intake. It is used

MAF Mass Air Flow Engine
together with a MAF sensor.
Service that allows transmission and reception of

Multimedia Messaging
MMS Communication short text or voice messages, or pictures between
Service
cell phones.
Properties of electrical or hydraulic circuits. Circuit is

Electrical system, Hydraulic
NC Normally Closed closed when it is not activated, and opens when it is
system
activated.

NO Normally Open open when it is not activated, and closes when it is
system
activated.
Open-center Load Hydraulic system that can operate more than one
OLSS Hydraulic system
Sensing System actuator at the same time regardless of the load.
PC Pressure Compensation Hydraulic system A function used to correct oil pressure.
00-26 HD465-8, HD605-8

00 INDEX AND FOREWORD ABBREVIATIONS

and system)
Steering System in which a controller examines data from

Palm Command Control each lever, pedal, and knob, and performs
PCCS
System (D) necessary electronic control of the engine and
transmission.
This valve is installed at the inlet port of pump, and it

PCV Pre-stroke Control Valve Engine adjusts fuel intake quantity to control fuel volume of
supply pump.
Proportional Pressure This system is used for controlling pressures. It

PPC Hydraulic system
Control moves actuators in proportion to oil pressure.
Hydraulic system
PPM Piston Pump and Motor Piston hydraulic pump and motor.
(D, PC, etc)
PTO Power Take Off Power train system Power take-off mechanism.
Power Tilt and power Work equipment This function performs hydraulic control of the tilt
PTP
Pitch dozer (D) and angle of the Bulldozer blade.
If a machine tilts over, this structure protects the

operator who wears a seat belt from injury.
Roll-Over Protective (Operator protection structure)
ROPS Cab and canopy
Structure
This performance is standardized as ISO 3471 or
ISO 12117-2.
It is an exhaust gas conditioner, using urea water

Selective Catalytic which converts nitrogen oxides (NOx) to harmless
SCR Urea SCR system
Reduction nitrogen and water. It is also known part of the name
of related devices.
Le Systeme International Abbreviation for "Le Systeme International d'

SI d' Unites (International Unit Unites". It is the accepted unit system and "one unit
unit system) for one quantity" is the basic principle applied,
Refers to an actuator that moves by magnetic force

SOL Solenoid Electrical system
when the solenoid is energized.

Tip-Over Protective
TOPS Cab and canopy (Protective function for compact excavators against
Structure
overturning)
TWV 2-Way Valve Hydraulic system Solenoid valve that switches direction of flow.
Variable Geometry A turbocharger which can change the pattern of the

VGT Engine
Turbocharger exhaust flow area.
Function providing both high production and low fuel

Variable HorsePower
VHPC Engine control consumption by fine control of the maximum power
Control
of the machine.
*: Code for applicable machine model

D: Bulldozer
HD: Dump truck
HM: Articulate dump truck
PC: Hydraulic excavator
WA: Wheel loader
HD465-8, HD605-8 00-27

List of abbreviations used in the circuit diagrams
Abbreviation Terms shown completely
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission
00-28 HD465-8, HD605-8

00 INDEX AND FOREWORD HOW TO READ THE SHOP MANUAL
FOREWORD, SAFETY, BASIC INFORMATION

HOW TO READ THE SHOP MANUAL
q Some of the machine attachments and options described in this shop manual may not be available. If they are required,
consult your Komatsu distributor.
q The material and specifications are subject to change without notice.
q Shop Manuals are available for machine and engines. For the engine, see the shop manual for the machine which has the
same model engine.
q Machine may differ from the figure contained in this manual. A typical model is shown in the illustrations of this shop manual.
Configuration of the shop manual

This shop manual contains technical information necessary to perform repairs and service. It is divided into the chapters that
follow.
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 FUNC-
TION" is an aid to understand and troubleshoot each component.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure reason for test, adjust, and troubleshoot a problem.
Use the standard values table to make sure the standard values for test and adjust, and judge troubles when you troubleshoot
a problem.
30 TEST AND ADJUST
This section describes the test tools, the procedures for test and adjustment procedure of each part. The standard values and
repair limit for TEST AND ADJUST are described in the "STANDARD VALUE TABLE".
40 TROUBLESHOOTING
This section describes how to troubleshoot failures and provides solution procedures by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation, disas-
semble, and assemble of components and parts. In addition, bolt and nut tighten values, quantity, and weight of the materials,
lubricants, and coolant necessary to this work is shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows the reason and
solution for disassemble and assemble.
80 THE OTHER INFORMATION
This section describes structure and function, test, adjust, and how to troubleshoot for all of other components or equipment
not classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.
Symbols
Important safety and quality items are identified with these symbols to ensure the shop manual is used correctly.
HD465-8, HD605-8 00-29

HOW TO READ THE SHOP MANUAL 00 INDEX AND FOREWORD
Symbol Item Remark
If not prevented, this symbol indicates a very dangerous situation which will
Danger
cause death or serious injury.
If not prevented, this symbol indicates a potentially dangerous situation which

Warning
will cause death or serious injury.
If not prevented, this symbol indicates a potentially dangerous situation which

Caution
will cause injury or property damage around the machine.
This symbol indicates the weight of a part or component is an item that requires
Weight
careful sling selection.
This symbol indicates the tighten value for parts which requires special care in
Tighten Values
assemble work.
Layer This signal indicates an area to layer with glue or grease in assembly work.
Oil and coolant This signal indicates an area to supply oil, coolant, and the quantity.
Drain This signal indicates an area to drain oil, coolant and the quantity.
Signal word
Signal word for a notification described as follows.
Symbol Item Remark

If the precaution of this signal word is not observed, machine damage or
NOTICE Notice
shorter service life may occur.
REMARK Remark This signal word contains useful information to know.
Unit
International System of Units (SI) is used in this manual. Units used in the past are given in { }.
00-30 HD465-8, HD605-8

00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION
SAFETY NOTICE FOR OPERATION

q Appropriate service and repair are very important to ensure safe operation of the machine. The shop manuals describe the
good and safe service and repair procedures recommended by Komatsu. Some of the service and repair procedures re-
quire special tools made by Komatsu for special functions.
q The symbol mark is indicated for such matters that require special precautions. When work indicated with this
warning mark is performed, refer to the instructions with special care. Should a dangerous situation occur during such work,
be sure to keep safe and take all necessary measures.
Safety matters
q Good organized workplace
q Correct work clothes
q Obey work standard
q Application of hand signals
q Prohibit persons not approved to operate or handle the machine
q Safety check before you start work
q Wear safety glasses when you clean or grind
q Wear welding goggles and protective clothes for welding
q Be in good condition, and prepare your work area correctly
q Always be alert and careful.
General precautions
k If the machine is handled incorrectly, it is dangerous. Read and understand what is described in the operation and
maintenance manual before operation. Read and understand what is described in this manual before operation.
q Read and understand the safety labels on the machine before you perform any repairs. For the locations of the safety labels
explanation of precautions, see Operation and Maintenance Manual.
q Organize tools and parts removed in the work area. Always keep the work area clean and make sure that there is no dust,
dirt, oil, or water on the floor. Smoke only in the approved areas. Never smoke while you work.
q Keep all tools in good condition, learn the correct procedure, and use the proper tools. Examine the tools, machine, lift truck,
fully before you start work.
q Always wear safety equipment when you perform any operation.
Do not wear loose clothes.
HD465-8, HD605-8 00-31

SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD
q Always wear the protective eyeglasses when you hit parts with a
hammer.
q Always wear the protective eyeglasses when you grind parts.
q When you perform any operation with other persons, always agree
on the procedure before you start. Be clear in verbal communica-
tion, and observe hand signals. Hang "REPAIR" warning tag in the
operator's cab before you start work.
q Work and operation which require license or approved performed
by a qualified person.
,&
q Welding repairs performed by approved and experienced welders.
When you perform welding, always wear gloves, welding goggles,
cap and other clothes for welding work.
q Warm up before you start work with exercise which increases alertness and the range of movement to prevent injury.
q Avoid long work, and take stop at times to keep in good condition. Stop work in a safe area.
Preliminary work precautions

q Put the machine on level ground, and apply the parking brake. Chock the wheels or tracks to prevent machine movement
before you make any repairs.
q Lower the work equipment to the ground before you start work. If this is not possible, engage the lock pin or use blocks to
prevent the work equipment from movement. In addition, be sure to lock all the control levers and hang "REPAIR" warning
tag on them.
q When you perform disassemble or assemble work, support the machine with blocks, jacks, or stays before you start.
q Remove all mud and oil from the steps before you go up and down
on the machine. Always use the handrail, or steps when you go up
and down on the machine. Never jump on or off the machine. Re-
pair or replace damaged steps or handrails immediately.
,&
Precautions during work

q For the machine with the battery disconnect switch, check before you start the work that the system operating lamp is OFF.
Then, turn the battery disconnect switch to off (○) position.
REMARK
If the battery disconnect switch is a key type, remove the key after it is turned off (○). For the machine without a battery
disconnect switch, turn the start switch to off position, wait for two minutes or more before you start work. Disconnect the
battery, start with the negative (-) terminal first.
q For the machine with quickly removed battery terminal (-), make sure that system operating lamp is off before you start
work. Then, disconnect the battery terminal (-).
REMARK
For the machine without the system in operation lamp, turn the start switch to off position, wait for two minutes or more
before start work. Disconnect the battery terminal (-).
q Before you start work, disconnect and remove oil, fuel, water, or air from the system. When you remove the cap, oil filter,
drain plug, or oil pressure plug, it do this slowly otherwise the oil spills.
q When you remove or install the oil level plug or the piping in the fuel circuit, wait 30 seconds or longer after the engine is
stopped. Start the work after the remaining pressure is released from the fuel circuit.
00-32 HD465-8, HD605-8

q The coolant and oil in the circuits are hot when the engine is shut
down. Be careful not to become burned. Wait for the oil and cool-
ant to cool before you perform any work on the oil or coolant cir-
cuits.
q Before you start work, stop the engine. When you work on or
around parts that move, stop the engine. When you examine the
machine without shutdown of the engine to measure oil pressure,
speed, or temperatures, take extreme care not to become caught
in parts that move.
q When you must raise a heavy component (heavier than 25 kg),
use a hoist or crane. Before you start work, check that the slings
(wire ropes, web slings, chains, or hooks) are free from damage.
Always use slings with approved capacity and install them into
proper positions. Operate the hoist or crane slowly to prevent the
component from touch of any other part. Do not work on any part
lifted by a hoist or crane.
q When you remove a part which is in internal pressure or in reaction
force of a spring, always leave 2 bolts in positions. Loosen those
2 bolts gradually and in one and then the other to release the pres-
sure, and then remove the part.
q When you remove a component, do not break or damage the elec-
trical wires. Damaged wires may cause a fire.
q When you remove piping, do not spill the fuel or oil. If any fuel or
oil spills onto the floor, wipe it up immediately. Fuel or oil on the
floor can cause you to slip or cause fires.
,&
q Do not use gasoline to clean parts as a general rule. Do not use
gasoline to clean electrical parts, in particular.
q Be sure to assemble all parts again in their initial positions. Replace any damaged parts with new parts. When you install
hoses and wire harnesses, be sure that you do not cause damage to them by contact with other parts when the machine
is operated.
q When you install high-pressure hoses and lines, make sure that they are not twisted. Damaged hoses and lines are dan-
gerous, be very careful when you install hoses and lines on high-pressure circuits. In addition, make sure that high-pressure
hoses and lines are correctly installed.
HD465-8, HD605-8 00-33

q When you assemble or install parts, always tighten them to the specified value. When you install protection parts such as
guards, or parts which vibrate or rotate at high speed, make sure that they are installed correctly.
q Never use your fingers or hand when you align two holes. Be careful not to get your fingers caught in a hole.
q Make sure that the measurement tools are correctly installed when you measure hydraulic pressure.
q Take care when you remove or install the tracks machines. Since the track shoe may disconnect suddenly when you re-
move it, never let anyone near or at either end of the track shoe.
q If the engine is operated for a long time in a closed area with un-
satisfactory airflow, there may be dangerous gas. Open the win-
dows and doors to ventilate the area correctly.
,&
Hand signals and use of sling precautions

q One appointed worker make hand signals and coworkers must communicate with each other frequently. The appointed
worker must make hand signals in clear view of the operator's seat and view of the work conditions. The signal worker must
stay in front of the load and guide the operator safely.
k Never stay below the load.
k Do not move a load over a person.
k Never step on the load.
k Do not hold or prevent the load from swinging with your hands.
k Personal must move to a safe area away from lifted load.
q Examine the lift slings before you start work.
q Use gloves during sling work. (Put on leather gloves, if available.)
q Make sure the load weight is balanced and in the middle.
q Use the proper sling corresponding to the weight of the load and procedure to attach them. If too thick wire ropes are used
to sling a light load, the load may slip and fall.
q Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire
ropes symmetrically.
k When you lift with one rope sling, it may allow load to turn or slip from its initial position. This could cause an
accident.
q Attachment angle must be 60 °or smaller as a rule.
q When you sling a heavy load (25 kg or heavier), the angle of the rope must be thinner than the hook.
REMARK
When you sling a load with 2 or more ropes, the force applied to
each rope increases with the increase in hang angle. The figure
below shows the difference of permitted load in kN {kg} when a lift
is made with 2 ropes. Each rope is allowed to sling a maximum of
9.8 kN {1000 kg} vertically, at different hang angles. When the 2
ropes sling a load vertically, they can sling a maximum of 2000 kg
of total weight. This weight is reduced to 1000 kg when the 2 ropes
are attached at an angle of 120 °. If the 2 ropes lift a 2000 kg load
at an angle of 150 °. Each rope is applied to a force as large as
39.2 kN {4000 kg}.
q When you install wire ropes to an angular load, apply pads to protect the wire ropes. If the load may slip, apply proper ma-
terial to prevent the wire rope from slip.
q Use the specified eye bolts and attach them to wire ropes or chains with shackles.
00-34 HD465-8, HD605-8

q Attach wire ropes to the middle part of the hook.

k If hooks does not have a safety lock system, do not use it.
k Attachment of sling near the point of the hook may cause
the rope to slip off the hook.
REMARK
The hook is the strongest at its middle part.
q Never use a damaged rope sling (A), reduced dimension (B), or

bends (C). There is a dangerous that the rope may break during
the lift operation.
Precautions for sling up
q Tighten sling slowly with crane. When you settle the wire ropes, do
not grasp, but push them from outer edge. If you grasp the sling,
injury may occur.
q After the wire ropes are tight, stop the crane and examine the con-
dition of the load, wire ropes, and pads.
q If the load is not stable, the wire rope or chains are twisted, lower
the load adjust slings and lift again.
q Do not lift loads on an angle.
Precautions for sling down
q When you lower load, stop it temporarily at 30 cm above the floor, and then lower it slowly.
q Make sure that the load is stable, and then remove the sling.
q Remove bends and dirt from the wire ropes and chains and put them in the specified area.
Precautions when using a mobile crane

REMARK
Read Operation and Maintenance Manual of the crane carefully and operate the crane safely.
Precautions when using an overhead crane

k When you lift a heavy component (heavier than 25 kg), use a winch or crane.
HD465-8, HD605-8 00-35

REMARK
Weight of components heavier than 25 kg are shown with symbol in the "DISASSEMBLY AND ASSEMBLY".
q Before you start work, examine the wire ropes, brake, clutch, controller over wind devices. Test ground circuit, crane safety
device, caution lamps and examine the safety items.
q Observe the signals for sling work.
q Operate the winch in safe area.
q Be sure to examine the directions on the indication plate (north, south, east and west) on the crane operation switches.
q Do not sling a load at an angle. Do not move the crane while load has movement.
q Do not raise or lower a load while the crane move longitudinally or laterally.
q Do not pull a sling.
q When you lift a load, stop it just after it clears the ground, examine that the loads is safe, and then finish the lift.
q Inspect the travel routing and lift a load to a safe height.
q Put the control switch in a position where it is not an obstruction to the work.
q After you operate the crane, do not let the control switch swing.
q Locate the position of the electrical primary switch so you can turn it off immediately in an emergency.
q If the hoist stops because of an electrical failure, turn off the primary switch. When you set a ground fault circuit, make
sure that the devices related to that circuit are not set to operate.
q Stop the hoist operation when the area becomes obstructed.
q After you complete the work, and raise the hook a minimum 2 m above the floor. Do not leave the sling installed to the
hook.
Select wire ropes

Select adequate wire rope depends on the weight of the parts to be lifted, refer to the table below.
REMARK
The approved load is calculated with one sixth (safety factor of 6) of the failure load of the rope.
Wire rope (JIS G3525 6x37-A type) (Standard Z twist wire not galvanized)
Nominal dimension of rope (mm) Approved load (kN {t})

10 8.8 {0.9}
12 12.7 {1.3}
14 17.3 {1.7}
16 22.6 {2.3}
18 28.6 {2.9}
20 35.3 {3.6}
25 55.3 {5.6}
30 79.6 {8.1}
40 141.6 {14.4}
50 221.6 {22.6}
60 318.3 {32.4}
00-36 HD465-8, HD605-8

Precautions when you disconnect air conditioner piping

NOTICE
When you replace the air conditioner unit, air conditioner compressor, condenser or receiver drier, collect the air con-
ditioner gas (R134a) from the air conditioner circuit before you disconnect the air conditioner hoses.
REMARK
q Request a qualified person to collect, add and fill the air conditioner gas (R134a).
q Never release air conditioner gas (R134a) to the atmosphere.
k Put on protective eyeglasses, gloves and work wear. Otherwise, when air conditioner gas (R134a) gets in your
eyes, you may lose your sight. If it touches your skin, it may cause injury.
q When you loosen the air conditioner hoses and piping, be sure to use 2 wrenches.
Precautions for air conditioner piping

q When you install the air conditioner piping, be careful, to keep dirt, contamination and water from the hose.
q Make sure that the o-rings are attached to the joints when you connect the air conditioner piping.
q Do not use an o-ring again. It is deformed and deteriorated.
q When you remove the o-rings, use a soft tool to prevent damage to piping.
q Make sure the o-ring is not damaged or deteriorated.
q Apply oil for air conditioner gas (R134a) to o-ring.
REMARK
Do not apply oil to the bolts, nuts or unions.
Manufacturer Part name

DENSO ND-OIL8
VALEO THERMAL SYSTEMS ZXL100PG (PAG46 or equivalent)
SANDEN SP-10
When you tighten nuts on air conditioner hoses and piping, be sure to use 2 wrenches. Use one wrench to hold and tighten the
nut with the other wrench. (Use a wrench to tighten).
HD465-8, HD605-8 00-37

REMARK
q The figure shows an example of fitting of o-ring.
q An o-ring is attached to each joint of the air conditioner piping.
For tighten values, see "THE OTHER INFORMATION", "PRECAU-
TIONS FOR DISCONNECTING AND CONNECTING HOSES AND
TUBES IN AIR CONDITIONER PIPINGS".
00-38 HD465-8, HD605-8

00 INDEX AND FOREWORD PRECAUTIONS TO PREVENT FIRE
PRECAUTIONS TO PREVENT FIRE

Fire caused by fuel, oil, coolant or window washer fluid
Do not bring any open flame near fuel, oil, and coolant or window
washer fluid. Always observe as follows.
q Do not smoke or use open flame near fuel or other flammable ma-
terials.
q Shut down the engine before you add fuel.
q Do not leave the machine while you add fuel or oil.
q Tighten the fuel and oil caps correctly.
q Be careful not to spill fuel on hot surfaces or on parts of the elec-
trical system.
,&
q After you add fuel or oil, wipe up any spilled fuel or oil.
q Put greasy rags and other flammable materials into a safe contain-
er to maintain safety at the workplace.
q When you clean parts with oil, use a non-flammable oil. Do not use
diesel oil or gasoline. There is dangerous that they may catch fire.
q Do not weld or cut any pipes or hoses that contain flammable liq-
uids.
q Determine well-ventilated areas for to store oil and fuel. Keep the
oil and fuel in the specified area and do not allow unauthorized
persons to enter.
q When you grind or weld on the machine, move any flammable ma-
terials to a safe area before you start.
,&
Fire caused by accumulation or flammable material

q Remove any dry leaves, particles, or any other flammable materials accumulated or attached to or around the engine ex-
haust system.
q To prevent fires, remove any flammable materials such as dry leaves, particles, or any other flammable materials accumu-
lated around the cooling system.
Fire caused from electrical wires

Short circuits in the electrical system can cause fire. Always observe as follows.
q Keep all the electrical connections clean and correctly tightened.
q Examine wires each day for proper installation or damage. Attach any loose connectors or wire clamps. Repair or replace
any damaged wires.
Fire caused by piping

Make sure that all clamps for the hoses and piping, guards, and mounts are correctly attached in position.
If loose, they may vibrate during operation and rub against other parts. This is dangerous, may damage the hoses and cause
high-pressure oil to leak cause a fire or serious personal injury or death.
Fire around the machine because of hot exhaust gas

This machine is equipped with KDPF (Komatsu Diesel Particulate filter).
KDPF is a system to clean exhaust gas by removal of soot in exhaust gas. During regeneration, the temperature of exhaust
gas may be higher than that of standard models. Do not bring any flammable materials near exhaust pipes.
q When there are dry leaves or pieces of contamination near the work area, set the system to disable the regeneration before
you start work. Do this to prevent a fire hazard because of hot exhaust gas.
See the Operation and Maintenance Manual for the setting procedure.
Explosion caused by lighting equipment

q When you measure fuel, oil, battery electrolyte, or coolant, always use safe light equipment with explosion specifications.
HD465-8, HD605-8 00-39

ACTIONS IF FIRE OCCURS 00 INDEX AND FOREWORD
q When you use the electrical system for the lighting equipment from the machine, use the instructions in the Operation and
Maintenance Manual.
ACTIONS IF FIRE OCCURS

q Turn the start switch to OFF position to stop the engine.
q Use the handrails and steps to move off the machine.
q Do not jump off the machine. You may fall and be injured.
q The fumes generated by a fire contain harmful materials which have a bad influence on your body when they are inhaled.
Do not breathe the fumes.
q After a fire, there may be harmful compounds left. If they touch your skin, they may injury your body.
Be sure to wear rubber gloves when you handle the materials left after the fire.
When you wear work gloves, wear rubber gloves below them.
PRECAUTIONS FOR REMOVAL OF DANGEROUS MATERIALS

To prevent pollution, use these procedures for removal unwanted materials.
q Always drain the oil from your machine in containers. Never drain
the oil or coolant directly onto the ground, dump into drain sys-
tems, waterway, or lakes.
q Obey appropriate laws and regulations when you discard harmful
objects such as oil, fuel, coolant,solvent, filters, batteries, and
DEF.
Avoid burned rubber or plastics which produce a toxic gas that is harmful to people.
q When discard parts made of rubber or plastics (hoses, cables, and harnesses), always comply with the local regulations.
00-40 HD465-8, HD605-8

00 INDEX AND FOREWORD STEPS NECESSARY TO MEET EXHAUST GAS REGULATIONS
STEPS NECESSARY TO MEET EXHAUST GAS REGULATIONS

This machine meets either of Tier4 Final for North America or Stage IV Europe regulations.
This machine is equipped with two exhaust treatment systems:
q Komatsu Diesel Particulate Filter (hereafter KDPF): A device which captures soot in the exhaust gas to purify exhaust gas.
This procedure burns the soot and referred to as "regeneration".
q Urea SCR system: A device which decomposes the toxic nitrogen oxides (NOx) mixed in the exhaust gas into harmless
nitrogen and water. Spraying aqueous urea solution into the exhaust gas produces a reaction between the nitrogen oxides
and ammonia generated from the urea solution and decomposes the nitrogen oxides into nitrogen and water.
Either AdBlue® or DEF may be used as the aqueous urea solution for the SCR system.
AdBlue® is a registered trade-mark of VDA (Verband der Automobilindustrie e.V.: Automobile Association of Germany).
DEF is the abbreviation for Diesel Exhaust Fluid.
Commercial AdBlue® that is API approved and meets all the requirements defined in ISO 22241-1.
This solution will be represented as AdBlue® throughout this manual.
About AdBlue®
AdBlue® is necessary for the urea SCR system. DEF is a colorless transparent 32.5% urea solution. Urea as main
constituent is a material which is used for cosmetics, medical and pharmaceutical products, and fertilizer, etc.
If you add any additional additive agents or water to AdBlue® and use it, the devices will not function properly, and
conformance to the exhaust gas regulations will be lost.
q In Europe, use AdBlue®.
q In North America, use DEF (Diesel Exhaust Fluid) which is certified by API (American Petroleum Institute). DEF Certifica-
tion Mark shown as follows. Look for the API DEF Certification Mark when purchasing DEF.
API Diesel Exhaust Fluid Certification Mark is the trade
mark of API (American Petroleum Institute).
HD465-8, HD605-8 00-41

PRECAUTIONS FOR DEF 00 INDEX AND FOREWORD
PRECAUTIONS FOR DEF

GENERAL CHARACTER AND PRECAUTIONS FOR USAGE
DEF is a colorless transparent 32.5% urea solution. Urea is the primary material used in medical products, and fertilizer. These
situations require immediate step:
q If it gets on your skin, it may cause injury. Immediately take the dirty work wear and shoes off and clean with water. In ad-
dition, clean with a solution of soap and water. If your skin becomes red or begins to hurt, immediately consult a doctor.
q Do not induce vomit when swallowed. If swallowed, rinse mouth fully with water and consult a doctor.
q Avoid contact with the eyes. If there is contact, flush with clean water for several minutes and consult a doctor.
q Wear protective eyeglasses when near DEF to protect from solution spray in your eyes. Wear rubber gloves when you
perform work handling DEF to avoid skin contact.
PRECAUTIONS WHEN YOU ADD DEF
Do not put fluid other than DEF into DEF tank. If diesel fuel or gasoline is added into the tank, it can cause a fire. Some fluids
or agents added can create and emit a toxic gas.
When you open the cap of DEF tank of the machine, ammonia vapor may release. Keep your face away from the fill port when
open or fill tank.
PRECAUTIONS WHEN YOU STORE DEF
If the temperature of DEF becomes high, harmful ammonia gas is released. Completely seal the container to be kept. When
you open the container, perform in good ventilated area.
Avoid sunlight when you store AdBlue/DEF. Always use the initial container. Do not replace the container of AdBlue/DEF with
another one. If AdBlue/DEF is kept in an iron or aluminum container, toxic gas may develop or corrode the container.
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE
AdBlue/DEF is nonflammable, however, in the case of a fire it may generate an ammonia gas. Act on the “STEPS IF FIRE
OCCURS”.
If AdBlue/DEF is spilled, immediately wipe and clean the area with water. If spilled AdBlue/DEF is left and the area is not
cleaned, toxic gas or corrosive material and caused a chemical reaction.
THE OTHER PRECAUTIONS
When you discard AdBlue/DEF, treat it as a toxic material. For the procedure, refer to “PRECAUTIONS FOR REMOVAL OF
DANGEROUS MATERIALS”. The container of AdBlue/DEF is handled as a toxic material.
Never use an iron or aluminum container when you dispose AdBlue/DEF fluid, because toxic gas may develop and or corrode
the container. Use a container made of PP, PE or stainless steel when you handle AdBlue/DEF.
Do not touch any fluid from urea SCR. This fluid becomes acid with the influence of fuel and oxidation catalyzers. If it gets on
your skin, fully clean it off with water.
Never relocate or modify the exhaust gas after treatment device. Harmful gas is released and causes serious damage to the
environment and violates emission laws.
00-42 HD465-8, HD605-8

00 INDEX AND FOREWORD DEF STORAGE PRECAUTIONS
DEF STORAGE PRECAUTIONS

q If the temperature of AdBlue/DEF becomes high, harmful ammonia gas is generated. Completely seal up container to be
kept. When you open the container, open in a good ventilated area.
q When you store AdBlue/DEF, prevent direct sunlight. Always use the initial container. Do not replace the container of Ad-
Blue/DEF with another one. If AdBlue/DEF is kept in an iron or aluminum container, toxic gas may develop or corrode the
container.
q AdBlue/DEF freezes at –11 °C. The recommended temperature when stored is -5 °C or greater.
The relation between the upper temperature limit and the length of time AdBlue/DEF is stored is shown in the table.
Temperature of area Stored period

Maximum 10 °C Maximum 36 months
*: Do not keep AdBlue/DEF in the temperature of 35 °C or greater.

How you handle AdBlue/DEF in cold weather
q AdBlue/DEF freezes at –11 °C.
AdBlue/DEF may freeze and break devices and parts in the DEF tank. Add AdBlue/DEF to the specified quantity for cold
weather.
q In cold weather, keep AdBlue/DEF and the machine where the temperature is at –11 °C or higher to prevent the tank from
freeze.
Drain AdBlue/DEF to prevent it from freeze.
HD465-8, HD605-8 00-43

PRECAUTIONS WHEN YOU HANDLE HYDRAULIC EQUIPMENT 00 INDEX AND FOREWORD
PRECAUTIONS WHEN YOU HANDLE HYDRAULIC EQUIPMENT

Because of high pressure and more precise hydraulic components, the most likely cause of a failure is dirt and contamination
material in the hydraulic circuit. Special care is necessary when you add hydraulic oil, or when disassemble, or assemble hy-
draulic components.
Select an appropriate workplace

q In wet, windy or dusty environment, do not add hydraulic oil, change filters, or repair the machine.
Disassemble and maintenance work outdoors

q Outdoors, there is a risk of dust go into the component during dis-
assemble or maintenance work. Replacement of the assembly is
recommended.
q Perform disassemble and maintenance work in a clean area.
Seal openings and prevent oil flow

Plug openings of the piping and the device which are removed to prevent unwanted material from go into components and oil
flow out.
NOTICE
Do not open, otherwise unwanted material may enter or oil leak out and harm the environment.
Do not discard oil without care. Ask for the proper dispose or bring it back to dispose it correctly.
REMARK
Cover the areas tightly with caps or bags.
Prevent unwanted materials during fill

q During the fill hydraulic oil, do not let unwanted materials enter the
hydraulic components.
q Clean the oil fill port and area and the fill pump.
q Fill using a filter transfer device which can filter the contaminations
accumulated in the oil while stored.
00-44 HD465-8, HD605-8

00 INDEX AND FOREWORD PRECAUTIONS WHEN YOU HANDLE HYDRAULIC EQUIPMENT
Change hydraulic oil while its temperature is high

q The higher the oil temperature is, the better it flows. Also, the contamination is released from the circuit. Perform the re-
placement while oil temperature is high.
q It is necessary to drain as all the old hydraulic oil as possible when you change oil.
NOTICE
Old hydraulic oil will contaminate new oil when mixed.
REMARK
Drain the old hydraulic oil not only from the hydraulic tank but also from the filter and drain plug in the circuit.
Flush operation
q System flush is required to filter out the contaminations in the hy-
draulic circuit after you disassemble and assemble, or you replace
the oil.
q Usually, the flush procedure is performed twice. Primary flush is
performed using special flush oil (1) and the secondary flush is
performed by using the specified hydraulic oil.
Clean operation
Perform oil flush to remove the contaminations in the hydraulic circuit after repair of the hydraulic components, pump, or control
valve.
REMARK
The oil flush equipment can remove the fine (approximately 3 μm) par-
ticles that the filter assembled in the hydraulic equipment cannot re-
move. Prevent, it is very good device.
HD465-8, HD605-8 00-45

PRECAUTIONS WHEN YOU DISCONNECT AND CONNECT PIPES 00 INDEX AND FOREWORD
PRECAUTIONS WHEN YOU DISCONNECT AND CONNECT PIPES

When you perform "TEST AND ADJUST" of the machine, "removal and installation" and "disassemble and assemble" of the
components, observe these precautions.
Precautions for removal and disassemble work

q If the cooling system contains coolant, discard it correctly. Do not drain on the ground, or drains.
q After you disconnect hoses and piping, plug them to prevent contamination.
q When you drain oil, prepare a container with sufficient capacity.
q Examine the match marks which indicate the installed position. Place the match marks in the positions where necessary
before removal of components to prevent any mistake when assemble.
q To prevent too much force applied to the wires, always hold the connectors when you disconnect harness connectors. Do
not pull the wires.
q Attach tags to wires and hoses until installation is done in the correct installed positions.
q Measure the thickness and number of shims.
q When you lift a component, use proper slings with sufficient load capacity.
q When using force screws to remove any component, tighten the force screws equally and in one and then the other.
q Before you remove any component, clean the area and cover the component to prevent any unwanted material from entry
after removal.
q After you disconnect the piping or open a pipe joint, install these plugs.
NOTICE
When you disassemble the machine, examine the part number in the Parts book and use the appropriate part that
matches the usage conditions.
REMARK
The part numbers of o-ring shown in the table indicate the temporary part number when disassemble and movement of the
machine.
Parts for disassemble of the face type seals on hoses and piping
Hose side Pipe joint side

Nominal number O-ring (3)
Plug (1) Nut (2)
02 07376-70210 02789-00210 02896-11008
03 07376-70315 02789-00315 02896-11009
04 07376-70422 02789-00422 02896-11012
05 07376-70522 02789-00522 02896-11015
06 07376-70628 02789-00628 02896-11018
00-46 HD465-8, HD605-8

00 INDEX AND FOREWORD PRECAUTIONS WHEN YOU DISCONNECT AND CONNECT PIPES
Parts for the removal of hoses and piping with taper seals
Hose side Pipe joint side

Nominal number
Plug (1) Nut (2)
02 07376-50210 07222-00210
03 07376-50315 07222-00312
04 07376-50422 07222-00414
05 07376-50522 07222-00515
06 07376-50628 07222-00616
10 07376-51034 07222-01018
12 07376-51234 07222-01219
14 07376-51443 07222-01422
Parts to disconnect split flange type on hoses and piping
Nomi Bolt pitch (mm) Hose side Tube side

nal
Sleeve head O-ring (4) Bolt (5) Washer (6)
num a b Flange (1) Split flange (2)
ber (3)
04 38.1 17.5 07379-00400 07371-30400 07378-10400 07000-12021 01010-80825 01643-50823

05 42.9 19.8 07379-00500 07371-30500 07378-10500 07000-13022 01010-80830 01643-50823
06 47.6 22.2 07379-00640 07371-30640 07378-10600 07000-13025 07372-51035 01643-51032
10 52.4 26.2 07379-01044 07371-31049 07378-11000 07000-13032 07372-51035 01643-51032
58.7 30.2 07379-01250 07371-31255 07378-11200 07000-13038 07372-51035 01643-51032
12
66.7 31.8 07379-01260 07371-51260 07378-11210 07000-13038 01010-81245 01643-51232
HD465-8, HD605-8 00-47

Nomi Bolt pitch (mm) Hose side Tube side

nal
Sleeve head O-ring (4) Bolt (5) Washer (6)
num a b Flange (1) Split flange (2)
ber (3)
69.9 35.8 07379-01460 07371-31465 07378-11400 07000-13048 07372-51240 01643-51232

14
79.4 36.5 07379-01470 07371-51470 07378-11410 07000-13048 01010-81455 01643-31445
77.8 42.8 07379-02071 07371-32076 07378-12000 07000-12060 07372-51240 01643-51232
20
96.8 44.5 07379-02080 07371-52080 07378-12010 07000-12060 01010-81865 01643-31845
24 88.9 50.8 07379-02484 07371-12484 07378-12400 07000-12070 07372-51240 01643-51232
30 106.4 62 07379-03010 07371-13010 07378-13000 07000-12085 07372-51650 01643-51645
34 120.6 69.8 07379-03411 07371-13411 07378-13400 07000-12100 07372-51650 01643-51645
40 130.2 77.8 07379-04012 07371-14012 07378-14000 07000-12110 07372-51650 01643-51645
50 152.4 92 07379-05011 07371-15011 07378-15000 07000-12135 07372-51655 01643-51645
Parts to remove an o-ring boss type joint
Nominal number Plug (1) O-ring (2)

08 07040-10807 07002-10823
10 07040-11007 07002-11023
12 07040-11209 07002-11223
14 07040-11409 07002-11423
16 07040-11612 07002-11623
18 07040-11812 07002-11823
20 07040-12012 07002-12034
24 07040-12412 07002-12434
30 07041-13012 07002-13034
33 07040-13316 07002-13334
36 07041-13612 07002-13634
42 07040-14220 07002-14234
52 07040-15223 07002-15234
00-48 HD465-8, HD605-8

Parts to remove taper pipe thread type joint
Nominal thread Plug (1)

Nominal number
dimension Square head type (A) Hex head (B)
01 R1/8 07042-00108 07043-00108
02 R1/4 07042-00211 07043-00211
03 R3/8 07042-00312 07043-00312
04 R1/2 07042-00415 07043-00415
06 R3/4 07042-00617 07043-00617
10 R1 07042-01019 07043-01019
12 R11/4 07042-01222 07043-01222
14 R11/2 07042-01422 07043-01422
20 R2 07042-02026 07043-02026
Precautions for installation and assembly work

q Tighten the bolts and nuts to the specified value (KES) unless otherwise told.
q Install the hoses without bends or touch. If there are any clamps, correctly attach them.
q Replace all of the gaskets, o-rings, pins, and lock plates with new.
q Bend the pins and lock plates correctly.
q When you apply adhesive, clean the surface and apply 2 to 3 drops to the threads.
q When you apply gasket material, clean the surface, and apply it equally after you make sure that the surface is free from
dust or damage.
q Clean all of the parts. If there is any damage or rust found on them, repair it.
q Apply engine oil to the parts that turn or slide on surfaces.
q Apply molybdenum disulfide lubricant (LM-P) to the surfaces of installed parts.
q After you install snap rings, check that is set in the groove completely.
q When you connect wiring harness connectors, clean the connectors to remove oil, dust, or water, then connect them tight.
q Use the eye bolts and screw them in correctly. Match the directions of the eyes and the hook.
q When you install split flanges, tighten the bolts equally in one and then the other to tighten equal.
q As a rule, apply gasket material (LG-5) or liquid sealant (LS-2) to the threads of each screw which receive pressure.
REMARK
If the threads are difficult to clean, you may use a seal tape.
When you wind seal tape onto a right-hand male screw, start clockwise from the 3 thread and move forward in direction of
the screw end.
HD465-8, HD605-8 00-49

NOTICE
If the seal tape is wound counterclockwise, it may become loose when turned in, and it may come off. If the sealed
point is pushed out, it may cause oil leakage.
NOTICE
When you assemble hydraulic equipment such as cylinders, pumps and piping. Be sure to bleed air from the hydraulic
circuit before you operate the machine.
1. Start the engine, and run it at low idle.
2. Perform the operation to extend and retract each cylinder of the work equipment. Stop at approximately 100 mm before the
travel end for 4 or 5 cycles.
3. Perform the operation to extend and retract each cylinder of the work equipment and stop it at the travel end for 3 or 4 times.
NOTICE
After repair is completed, or when you operate a machine which been stored for a long period. Bleed air from the hy-
draulic circuit using the same procedure.
Precaution at the time work is done

When you fill, coolant, oil and grease, or when you add of AdBlue/DEF
q For machines with urea SCR system, fill AdBlue/DEF to the specified level before you start the engine.
q Supply the specified quantity of grease to the work equipment parts.
q When the coolant is drained, be sure that the drain valve is correctly tightened. Then fill the coolant reservoir with Komatsu
recommends coolant to the specified level. Start the engine to circulate the coolant in the piping, and add the coolant to the
specified level again.
q When the hydraulic components are removed and installed, fill the tank with the oil Komatsu recommends to the specified
level. Start the engine to circulate the oil in the piping, and add the oil to the specified level again.
q If the hydraulic piping or hydraulic components are removed, be sure to bleed air from the system after assemble. (Refer
to "TEST AND ADJUST").
Test installed condition of cylinder heads and components
q Examine the cylinder head, intake and exhaust manifold mounts.
q If there are any fasteners loose, tighten them.
REMARK
For the tighten value, see "DISASSEMBLY AND ASSEMBLY".
Test engine piping for damage
Intake and exhaust system
Make sure that there is no damage to the piping, loose mount bolts, nuts or clamps, on air or exhaust gas leaks at the connec-
tions.
If there is any damage or gas leak, tighten or repair the part.
Cooling system
Make sure that there is no damage on the piping. No loose on mount bolts, nuts and clamps.
If there is any damage or leak, tighten or repair the part.
Fuel system
Make sure that there is no damage to the piping’s. No loose on mount bolts, nuts and clamps. No fuel leaks.
If there is any damage or fuel leak, tighten or repair the part.
Make sure the exhaust equipment and its installed parts are not damage
REMARK
When an equipment is described as an exhaust equipment, it is one of these. (The components installed on equipment are
different on model and machine specifications.)
q KDPF
q AdBlue/DEF mixing tube
q SCR assembly
00-50 HD465-8, HD605-8

q KDOC muffler
q Muffler
q Exhaust pipe
q Part which connects to these parts
Visually examine that there is no crack or damage on the exhaust equipment and its installation. If there is any damage, replace
the part.
Examine the exhaust equipment and mount bolts, nuts, and clamps on the installation.
If there is any damage, tighten the part.
Make sure function of exhaust system
REMARK
When equipment is described as an exhaust system, it is one of these. (The components on equipment are different, given the
machine model or specifications.)
q KDPF
q AdBlue/DEF mix pipe
q SCR assembly
q KDOC muffler
q Muffler
q Exhaust pipe
q Parts which connect to the exhaust system components
Make sure that there is no unusual noise compared to when the time when the machine was new.
If there is any unusual noise, repair KDPF or muffler, refer to "TROUBLESHOOTING" and "DISASSEMBLY AND ASSEMBLY".
HD465-8, HD605-8 00-51

PRECAUTIONS WHEN YOU HANDLE ELECTRICAL EQUIPMENT 00 INDEX AND FOREWORD
PRECAUTIONS WHEN YOU HANDLE ELECTRICAL EQUIPMENT

To maintain the performance of the machine over a long period and to prevent failures or troubles before, they occur. The cor-
rect "operation", "maintenance, machine inspection and "repairs" are necessary to be performed. This section deals particularly
with correct repair procedures for mechanical components and is pointed at better quality of repairs. For this function, it de-
scribes the work procedures in "Handling of electrical equipment".
Handle wire harness and connectors

q A wire harness have wires that connect one component to another
component. Connectors are used to connect and disconnect one
wire from another wire, and covers or pipe are used to protect the
wires.
q Compared with other electrical components, water, heat and vi-
bration effect wire harnesses. Furthermore, during inspection and
repair operations, they are frequently removed and installed again
and are likely to be deformed or damage. For this reason, it is nec-
essary to be very careful when you handle and maintain the wire
harnesses.
q If AdBlue/DEF is spilled on wire harnesses or connectors, it may
cause corrosion and defective connections. Be careful not to spill it over electrical equipment, wiring harness and connec-
tors, AdBlue/DEF is very corrosive.
Primary causes of failure in wiring harness

Defective connection of connectors (defective connection between male and female pins)
Problems with defective connection are likely to occur because the
male pin is not correctly engaged into the female. This is because one
or the two of pins are deformed or not position correctly or there is cor-
rosion on the pin surfaces. The corroded or damage surfaces may be-
come shiny again (and connection may become normal) by connect
and disconnect the connectors approximately 10 times.
Defective crimp or solder of connectors

The pins on male and female connectors are attached to wires by
crimp or solder procedure. If too much force is applied to the wire, the
connection (1) may become loose, and cause a defective connection
or failure.
00-52 HD465-8, HD605-8

00 INDEX AND FOREWORD PRECAUTIONS WHEN YOU HANDLE ELECTRICAL EQUIPMENT
Disconnected wire
If the wiring harness is pulled to disconnect the connector, or the com-
ponents are lifted with a crane while the wiring harness is connected,
or a heavy object hits the wiring harness, it may damage the crimp or
the soldered pins, or break the wiring harness.
Water go into the connector by high-pressure spray

The connector is made water taut, (water proof structure). But if
high-pressure water is sprayed directly on the connector, water may
enter the connector.
Do not spray water directly on the connector.
If the connector is sealed, entry of water will not drain. Once water
goes into the connector, water goes through pins to cause connection
problems. Dry the connector or take appropriate steps before you ap-
ply electricity.
Entry of water, dirt, or dust when you disconnect a connector
If any water, mud or dust is stuck to the outer surface of a connector,
it can enter into the connector when disconnected. Before you discon-
nect connectors, wipe off any water or dirt using a dry rag or dry with compressed air.
Oil, mud, or dust stuck to connector
If any oil or grease is stuck to the connector and an oil layer is on the
mating surface of the male and female pins, the oil prevents electrical
current flow through, which causes in defective connection. If any oil,
grease, dirt or dust is stuck to the connector, wipe off with a dry rag or
blow it with compressed air.
NOTICE
q When you wipe the joint of the connector, do not apply too much
force or deform the pins.
q If there is oil or water in the compressed air, it will contamination
the connector. Use clean filtered air.
HD465-8, HD605-8 00-53

PRECAUTIONS WHEN YOU HANDLE FUEL SYSTEM EQUIPMENT 00 INDEX AND FOREWORD
PRECAUTIONS WHEN YOU HANDLE FUEL SYSTEM EQUIPMENT

The machines equipped with common rail injection (CRI) have more precise parts than the parts used in the standard pump
and line systems. If unwanted material goes into this system, it may cause a failure. Use special care to prevent entry of the
unwanted material when servicing the fuel system.

Avoid when you add hydraulic oil, replace filters, or repair the machine in wet, windy weather, or dusty environment.
Seal opening
Plug the open pipes and the openings of the removed components with the caps or bags. To prevent unwanted material entry.
NOTICE
Do not leave open or fill with rags, otherwise unwanted material
may enter or oil leak oil harm the environment.
Do not discard the oil. Ask for proper procedure, or bring it back
to dispose it correctly.
How to clean parts when dirt is stuck

If any dirt or dust attaches to parts of the fuel system, clean fully.
Precautions when you replace fuel filter cartridge

Be sure to use the Komatsu genuine fuel filter cartridge.
NOTICE
Machines equipped with common rail injection (CRI) have more precise parts than the parts used in the standard fuel
pump and line systems. To prevent unwanted material from entry this system, the filter employs an especially high
performance of filter element. If a filter other than a Komatsu genuine filter is used, fuel system contamination and
damage may occur.
00-54 HD465-8, HD605-8

00 INDEX AND FOREWORD PRECAUTIONS WHEN YOU HANDLE INTAKE SYSTEM EQUIPMENT
PRECAUTIONS WHEN YOU HANDLE INTAKE SYSTEM EQUIP-

MENT
The machines equipped with a Komatsu Variable Geometry Turbocharger (VGT) have more precise parts than the parts used
in the standard turbocharger. If unwanted material goes into this system, it may cause a failure. Use special care to prevent
entry of the unwanted material when servicing the intake system.

When you add hydraulic oil, replace filters, or repair the machine, avoid wet or windy weather and dusty environment.
Seal opening
Plug the removed pipes and the openings of the removed components with caps or bags to prevent contamination entry.
NOTICE
Do not leave openings not covered, plug otherwise unwanted material may enter.
HD465-8, HD605-8 00-55

PRACTICAL USEAGE OF KOMTRAX 00 INDEX AND FOREWORD
PRACTICAL USEAGE OF KOMTRAX

Different information which KOMTRAX transmits using radio communication is useful to provide different services for the own-
er.
When KOMTRAX is installed and in operation, the KOMTRAX system displays machine information. This information is used
to troubleshoot problems, run system tests and evaluate machine performance.
Large-sized machines are equipped with KOMTRAX Plus which has more information available.
REMARK
KOMTRAX is not installed to the machine in some countries or areas.
Value of using KOMTRAX

q The location of the machine is examined on a computer.
q Operation information such as service meter, operation hours, fuel consumption, and failure code are shown.
q The operator can examine the hours used and replacement interval of serviceable parts, as fuel filter, hydraulic oil filter,
hydraulic oil and engine oil.
q Information of how machine is operated (idle time, travel time, dig time) be examined, and it is used to judge machine op-
eration condition.
q Different reports such as “Fuel burned, operation support”, “Operation reports is generated, and it is utilized as an advice
tool for the owner and operator.
q KOMTRAX Plus can record information, trend data, and snap shot data, to evaluate the condition of the machine. This data
is used and shown on a computer screens.
How to use KOMTRAX

KOMTRAX performs these functions.
q Fast movement to a request for immediate repair
1) Examine cautions and failure codes after you receive a repair request from the operator.
2) To immediately arrange necessary tools, replacement parts that agree with the shown failure code.
Locate the machine using the KOMTRAX machine location function.
q Preventative maintenance
1) When you examine service records with KOMTRAX, machines which have important failure codes have red or
yellow flag.
2) To examine the condition of the machine with the owner and prepare a visit to the machine.
3) To immediately arrange necessary tools, replacement parts in relation with the shown failure code.
q Practice of periodic maintenance and inspection service
1) To examine the service records to find the machine with usage limits of serviceable parts indicated by red flags.
2) Send an estimate of serviceable parts and labor for the repair to the owner.
3) To recommend service and inspections, refer to the service meter.
How to operate KOMTRAX

For the operation procedure of each screen of KOMTRAX, ask the key person in your Komatsu distributor.
00-56 HD465-8, HD605-8

00 INDEX AND FOREWORD DISCONNECT AND CONNECT PUSH PULL TYPE QUICK DISCONNECT
DISCONNECT AND CONNECT PUSH PULL TYPE QUICK DISCON-

NECT
REMARK
q Loosen the oil fill cap of the hydraulic tank slowly to release the pressure in the hydraulic tank.
q Provide an oil container to receive oil, some hydraulic oil flows out when the hose is disconnected.
PROCEDURE TO DISCONNECT AND CONNECT TYPE 1 PUSH PULL TYPE QUICK DIS-
CONNECT
Disconnection
1. Hold adapter (1), and push hose joint (2) into mating adapter (3).
REMARK
q Push it in approximately 3.5 mm.
q Do not hold rubber cap part (4).
2. While you have the adapter (3) engaged into hose side joint (2),
inner rubber cap (4) to adapter (3), side it in until it clicks.
3. Hold hose adapter (1) or hose (5), and pull it out.
REMARK
Provide an oil container to receive a quantity of hydraulic oil which
may flow out.
HD465-8, HD605-8 00-57

DISCONNECT AND CONNECT PUSH PULL TYPE QUICK DISCONNECT 00 INDEX AND FOREWORD
Connection
1. Hold hose adapter (1) or hose (5), and engage it in mating adapter
(3), align the parts.
REMARK
Do not hold rubber cap part (4).
2. After you put the hose in the adapter, pull it to make sure it
connected correctly.
REMARK
When the hose fitting is pulled back, the rubber cap moves approx-
imately 3.5 mm toward the hose, but it is not a problem.
CONNECT
Disconnection
1. Hold the adapter part and push body (2) straight until body (1)
touches surface (a) of the hex part at the male end.
2. While you keep the condition of step 1, turn lever (3) to the right
(clockwise).
00-58 HD465-8, HD605-8

00 INDEX AND FOREWORD DISCONNECT AND CONNECT PUSH PULL TYPE QUICK DISCONNECT
3. While you keep the conditions of steps 1 and 2, pull out full body
(2) to disconnect it.
REMARK
Provide an oil container to receive a quantity of hydraulic oil which
may flow out.
Connection
Hold the adapter part and push body (2) straight until slide (1) touches
surface (a) of the hex part at the male end.
CONNECT
Disconnection
1. Hold the adapter part and push body (2) straight until body (1)
touches surface (a) of the hex part at the male end.
2. While you keep the condition of step 1, push cover (3) straight until
it touches surface (a) of the hex part on the male side.
HD465-8, HD605-8 00-59

DISCONNECT AND CONNECT PUSH PULL TYPE QUICK DISCONNECT 00 INDEX AND FOREWORD
3. While you keep the conditions of steps 1 and 2, pull out full body
(2) to disconnect it.
REMARK
Provide an oil container to receive a quantity of hydraulic oil which may flow out.
Connection
Hold the adapter part and push body (2) straight until slide (1) touches
surface (a) of the hex part at the male end.
00-60 HD465-8, HD605-8

00 INDEX AND FOREWORD PRECAUTIONS FOR DISCONNECT AND CONNECT OF CONNECTORS
PRECAUTIONS FOR DISCONNECT AND CONNECT OF CONNEC-

TORS
Disconnect connectors
1. Hold the connectors when you disconnect.
When you disconnect the connectors, hold the connected part. If
the connector is fastened, loosen the connector completely, hold
the two, male and female connectors, and pull them apart.
NOTICE
Do not pull the connectors with one hand.
REMARK
If it is a lock type connector, pull it apart while you push the lock (1)
down with your thumb.
2. When you remove a connector from its mount

q The connector and clip have stops (2), which are engaged with
each other when connected.
q When you remove a connector from a clip, pull the connector
with the clip as you remove the stop.
NOTICE
If the connector is pushed up and down or to the right or left,
it may break the connector body.
3. Steps necessary after you remove the connectors

After you remove the connector, cover it with a bag to prevent en-
try of dust, dirt, oil, or water.
NOTICE
Be sure to cover the connectors before the machine is left
disassembled for a long period.
HD465-8, HD605-8 00-61

PRECAUTIONS FOR DISCONNECT AND CONNECT OF CONNECTORS 00 INDEX AND FOREWORD
Connect connectors
1. Examine the connector visually.
q Make sure that there is no dust, dirt, oil, or water stuck to the connector pins (joint part).
q Make sure that there is no deformation, defective pins, corrosion, or damage on the connector pins.
q Make sure that there is no damage or crack on the external surfaces of the connectors.
NOTICE
q If there is any dust, dirt, oil, or water on the connector, wipe it off with a dry rag. If there is water in the connector, blow
dry the inner side of the connector. Do not get the connector too hot, otherwise short circuit may occur.
q If there is any damage, replace the connector.
2. Connect the connector correctly
Position connector (1) correctly, and attach it in correctly.
REMARK
If the connector is lock type, engage it until it clicks.
3. Correct the seal extension and align the wiring harness.
q If the connector is with the seal, correct any extension of the seal. In addition, if the wiring harness is not aligned or the
clamp is out of position, adjust it to its correct position.
NOTICE
If the seal extension and align is not be repaired, remove the
clamp to adjust them.
q If the connector clamp is removed, be sure to install it back to

its initial position. Make sure that there is not loose.
00-62 HD465-8, HD605-8

00 INDEX AND FOREWORD PRECAUTIONS FOR DISCONNECT AND CONNECT OF CONNECTORS
Blow dry wiring harness

REMARK
If the wiring harness is dirty with oil and dust, wipe it off with a dry rag. Avoid water or high temperature pressured water. Do
not use high-pressure water directly on the wiring harness. If water gets directly on the connector, do as follows.
1. Disconnect the connector and wipe off the water with a dry rag.
NOTICE
If the connector is blown dry with compressed air, there is the
risk that oil in the air may cause a defective connection. Use
clean dry air.
2. Blow dry the inner side of the connector.

If water goes into the connector, blow dry connector.
NOTICE
Blow dry wit hot air could deformation or damage to the con-
nector. Care on the quantity of time you blow dry will prevent
the connector or related parts to become too hot.
3. Perform a continuity test on the connector.

After you dry the harness, connect T- Adapter (1). Perform a con-
tinuity test to measure for short or open circuits between pins
caused by water damage.
REMARK
After the connector is completely dried, reassemble them.
HD465-8, HD605-8 00-63

PRECAUTIONS FOR DISCONNECT AND CONNECT OF CONNECTORS 00 INDEX AND FOREWORD
Handle controller
k When you perform arc welding on the machine, disconnect all of the wiring harness connectors connected to the
controller. Attach an arc welding ground near the welding point.
NOTICE
q Controller are assembled with electronic circuits for control of mi-
cro-computers. These electronic circuits in the controller control
the machine, handle the controllers with care.
q Do not leave things on the controller.
q Cover the connector with tape and a bag. Do not touch the connect
part of connector.
q Do not leave the controller in an area where it will become wet.
q Do not put the controller on oil, water, soil or in any area where the
temperature is likely to be high.
Precautions for when you troubleshoot electrical circuits

q Be sure to turn the start switch to OFF position before you disconnect or connect the controller connectors.
q Before troubleshoot, examine all the related connectors for loose connection.
REMARK
Make sure the related connectors for their performance by disconnect and connect them several times.
q Be sure to connect all the disconnected connectors before continue to the next step.
NOTICE
If the start switch is turned to ON position while the connectors are disconnected, a different failure beside the
initial defective part is shown.
q When you perform the troubleshooting for the circuit, shake the related wires, harness, and connectors several times and
make sure the meter indication does not change.
NOTICE
If the value changes on the meter, there may be a defective connection in the circuit.
00-64 HD465-8, HD605-8

00 INDEX AND FOREWORD PROCEDURE TO DISCONNECT AND CONNECT DEUTSCH CONNECTOR
PROCEDURE TO DISCONNECT AND CONNECT DEUTSCH

CONNECTOR
Procedure to disconnect Deutsch connector
While you push locks (a) and (b) from each side related, pull out fe-
male connector (2).
Procedure to connect Deutsch connector

1. Push in female connector (2) horizontally, and engage it straight
until it clicks. (Arrow: x)
2. To examine whether locks (a) and (b) are completely engaged,
push the female connector (2) rock it vertically (in the arrow direc-
tion). (Arrow: x, y, z)
REMARK
Lock (a) in the figure is pulled down (not set completely), and lock
(b) is set completely.
HD465-8, HD605-8 00-65

PROCEDURE TO DISCONNECT AND CONNECT SLIDE LOCK CONNECTOR 00 INDEX AND FOREWORD
PROCEDURE TO DISCONNECT AND CONNECT SLIDE LOCK

CONNECTOR
Procedure to disconnect slide lock connector
(FRAMATOME-3, FRAMATOME-2)
1. Slide lock (L1) to the right.
2. While you push lock (L2), pull out connector (1) toward you.
REMARK
If part A does not free when lock (L2) is pushed, and if connector
(1) does not come out when it is pulled toward you. Push up part
A with a small flat-head screwdriver while you push lock (L2), and
then pull out connector (1) toward you.
Procedure to connect slide lock connector

(FRAMATOME-3, FRAMATOME- 2)
Engage it straight until it clicks.
Procedure to disconnect slide lock connector

(FRAMATOME-24)
1. Slide down lock (red) (L1).
2. While you push lock (L2), pull out connector (1).
REMARK
Lock (L2) is located behind connector (1) in the figure.
00-66 HD465-8, HD605-8

00 INDEX AND FOREWORD PROCEDURE TO DISCONNECT AND CONNECT SLIDE LOCK CONNECTOR
Procedure to connect slide lock connector (FRAMATOME-24)

HD465-8, HD605-8 00-67

PROCEDURE TO DISCONNECT AND CONNECT PULL TO LOCK TYPE CON-
NECTOR 00 INDEX AND FOREWORD
PROCEDURE TO DISCONNECT AND CONNECT PULL TO LOCK

TYPE CONNECTOR
Procedure to disconnect pull to lock type connector
Disconnect the connector (2), pull lock (B) on the wiring harness side
of the connector (2) outward.
Procedure to connect pull to lock type connector

Engage the connector correctly until it "clicks".
00-68 HD465-8, HD605-8

PROCEDURE TO DISCONNECT AND CONNECT PUSH TO LOCK TYPE CON-
00 INDEX AND FOREWORD NECTOR
PROCEDURE TO DISCONNECT AND CONNECT PUSH TO LOCK

TYPE CONNECTOR
Procedure to disconnect push to lock type connector (BOSCH-3)
While you push lock (C), pull on connector (3) in the direction of the arrow.
q 114 series
q 107 series
REMARK
If the lock is located on the underside, use flat-head screwdriver [1] when you cannot use your fingers.
While you push up lock (C) flat-head screwdriver [1], pull out connec-
tor (3) in the direction of the arrow.
Procedure to connect push to lock type connector (BOSCH-3)

HD465-8, HD605-8 00-69

PROCEDURE TO DISCONNECT AND CONNECT PUSH TO LOCK TYPE CON-
NECTOR 00 INDEX AND FOREWORD
Procedure to disconnect push to lock type connector (AMP-3)

While you push lock (E), pull on connector (5) in the direction of the
arrow.
Procedure to connect push to lock type connector (AMP-3)

Procedure to disconnect push to lock type connector (SUMITOMO-3)

While you push lock (E), pull on connector (5) in the direction of the
arrow.
REMARK
Pull the connector straight.
Procedure to connect push to lock type connector (SUMITOMO-3)

Procedure to disconnect push to lock type connector (SUMITOMO-4)

While you push lock (D), pull on connector (4) in the direction of the
arrow.
Procedure to connect push to lock type connector (SUMITOMO-4)

00-70 HD465-8, HD605-8

00 INDEX AND FOREWORD PROCEDURE TO DISCONNECT AND CONNECT TWIST TYPE CONNECTORS
PROCEDURE TO DISCONNECT AND CONNECT TWIST TYPE

CONNECTORS
Procedure to disconnect twist type connector
Turn housing (H1) to the left, and pull it out.
REMARK
Frame (H1) is left on the wiring harness side (6).
Procedure to connect twist type connector

1. Engage the connector to the end while you align its groove to the other.
2. Turn housing (H1) clockwise until it clicks.
HD465-8, HD605-8 00-71

HOW TO READ ELECTRICAL WIRE CODES 00 INDEX AND FOREWORD
HOW TO READ ELECTRICAL WIRE CODES

In the electrical circuit diagram, a symbol indicates the material, thickness, and color of each wire. The electrical wire code is
an aid to understand the electrical circuit diagram.
Example) AEX 0.85 L: Indicates heat-resistant, low-voltage blue wire for mobile equipment and number of 0.85
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in (Table 1).
AEX
Since the AV and AVS wires depends on dimension (nominal number), the symbols are not indicated on the
diagram.
Indicates dimension of wire by nominal number
0.85
Dimensions (Nominal number) are shown in (Table 2).
Indicates color of wire by color code.
L
Color codes are shown in (Table 3).
Type, symbol, and material

AV and AVS are different in only thickness and outer dimension. CAVS has a circular compressed wire. It differs from AV and
AVS in the outer dimension of the wire and thickness of the layer. AEX is similar to AV in thickness and outer dimension of the
outer layer but different from AV and AVS in material of the layer.
(Table 1)
Temperature
Type Symbol Wire material Outer layer material range (°C) in Example of use
use
Low-voltage
For large wires
wire for mobile AV
(Nominal number 5 and above)
usage
Thin-cover
low-voltage
General wires
wire for mobile AVS
(Nominal number 3 and lower)
usage Soft polyvinyl chloride -30 to +60
(Type 1) Annealed copper
Thin-cover for electrical
usage For the medium to small-size
low-voltage
excavators
wire for mobile CAVS
(Nominal number 1.25 and
usage
lower)
(Type 2)
Heat-resistant General wires for very
low-voltage Heat-resistant cross cold-weather specification
AEX -50 to +110
wire for mobile connected polyethylene Wires in high-temperature
usage position
Dimensions
00-72 HD465-8, HD605-8

00 INDEX AND FOREWORD HOW TO READ ELECTRICAL WIRE CODES
(Table 2)
Nominal number 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5

Number of
20 7 30 11 50 16 37 26 58 41 65
wires
Dimension
0.18 0.32 0.18 0.32 0.18 0.32 0.26 0.32 0.26 0.32 0.32
of each wire
Wire Wire cross

dimension 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d
(approximat 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
e.)
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 -
Lay
AV Standard - - - - - - - 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 - 3.8 4.6
Nominal number 8 15 20 30 40 50 60 85 100

Number of
50 84 41 70 85 108 127 169 217
wires
Dimension
0.45 0.45 0.80 0.80 0.80 0.80 0.80 0.80 0.80
of each wire
Wire Wire cross

dimension 7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d
(approximat 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
e.)
AVS Standard - - - - - - - - -
Lay
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
Nominal number 0.5f 0.5 0.75f 0.85 1.25f 1.25

Number of
- 7 - 11 - 16
wires
Dimension of Round
- Round compressed - Round compressed -
each wire compressed
Wire Wire cross

dimension - 0.56 - 0.88 - 1.29
area (mm2)
d
(approximate - 0.9 - 1.1 - 1.4
.)
Lay
CAVS Standard - 1.6 - 1.8 - 2.1
er D
REMARK
“f” of nominal number denotes "flexible".
HD465-8, HD605-8 00-73

HOW TO READ ELECTRICAL WIRE CODES 00 INDEX AND FOREWORD
Color codes table

(Table 3)
Color Code Color of wire Color Code Color of wire

B Black LgW Light green and White
Br Brown LgY Light green and Yellow
BrB Brown and Black LR Blue and Red
BrR Brown and Red LW Blue and White
BrW Brown and White LY Blue and Yellow
BrY Brown and Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red and Black
GB Green and Black RG Red and Green
GL Green and Blue RL Red and Blue
Gr Gray RW Red and White
GR Green and Red RY Red and Yellow
GW Green and White Sb Sky Blue
GY Green and Yellow Y Yellow
L Blue YB Yellow and Black
LB Blue and Black YG Yellow and Green
Lg Light green YL Yellow and Blue
LgB Light green and Black YR Yellow and Red
LgR Light green and Red YW Yellow and White
REMARK
In a color code that has 2 colors. The initial color is the back ground color and the second color is the color of the mark.
Example) GW indicates that the back ground is "Green" and mark is "White".
00-74 HD465-8, HD605-8

00 INDEX AND FOREWORD HOW TO READ ELECTRICAL WIRE CODES
Types of circuits and color codes
Type of wire AVS, AV, CAVS AEX

Charge R WG - - - - R -
Ground B - - - - - B -
Start R - - - - - R -
Light RW RB RY RG RL - O -
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB - L -
Type of circuit Br BrW BrR BrY BrB - - -
Lg LgR LgY LgB LgW - - -
O - - - - - - -
Others Gr - - - - - - -
P - - - - - - -
Sb - - - - - - -
Dg - - - - - - -
Ch - - - - - - -
HD465-8, HD605-8 00-75

EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 00 INDEX AND FOREWORD
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

The maintenance standard section shows the test results. When the machine is disassembled and assembled for maintenance,
these standards indicates whether it is necessary to replace parts or equipment. These terms give the results of tests.
Standard dimension and tolerance

q The completed dimension of a part has a small different from one to another.
q A standard dimension of a completed part is set, and an approved difference from that dimension is set for the part.
q The dimension set as the standard is the standard dimension and the permitted range of difference from this standard di-
mension is "tolerance".
q An indication example of a standard dimension and tolerance is shown in the table.
(The standard dimension is recorded on the left side and the tolerance is recorded with a positive or negative symbol on
the right side)
Example:
Standard dimension Tolerance

-0.022
120
-0.126
q The tolerance indicated in the text and a table as "standard dimension (upper limit of tolerance/ lower limit of tolerance)."
Example) 120 (-0.022/-0.126)
q Usually, the dimension of a hole and the dimension of the shaft into that hole are the same standard dimension. But have
a different tolerance for the hole and shaft. The fit determined by the tolerance.
q A dimension indication example of a shaft and hole is shown in the table.
(The standard dimension is recorded on the left. The tolerance of the shaft is recorded with a positive or negative symbol
in the middle. That of the hole on the right)
Tolerance
Standard dimension
Shaft Hole
-0.030 +0.046
60
-0.076 0
00-76 HD465-8, HD605-8

00 INDEX AND FOREWORD EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
Standard clearance and standard value

q The clearance made when new parts are assembled is called the
standard clearance, which indicates the range from minimum to
maximum clearance.
q When some parts are repaired, the clearance is generally adjusted
to the standard clearance.
q The value indicates performance and function of new products or
equivalent are ”standard value", which indicates a range or target
value.
q When some parts are repaired, the value of performance/ function
is set to the standard value.
Standard interference
q When the dimension of a hole is shown in the given standard dimension and tolerance table is smaller than that of the shaft,
the difference between those dimensions is "interference".
q Subtract the maximum dimension of the hole from the minimum dimension of the shaft and tell it (A). Subtract the minimum
dimension of the hole from the maximum dimension of the shaft and tell it (B). The range between (A) and (B) is "standard
interference".
q After you repair or replace parts, measure the dimension of their hole and shaft and check that the interference is in the
standard range.
Repair limit and approved value or permitted dimension

q The dimension of parts changes because of the wear or deformation while they are used. When the dimension changes
exceed certain value, parts not be used any longer. This value is called "repair limit".
q If a part is worn to the repair limit, repaired or replaced it.
q The performance and function of products lower while they are used. A value with which the product used without a problem
is “permitted value" or "permitted dimension".
q A product whose dimension is out of the permitted value, be repaired. In most cases the permitted values are general es-
timates through different tests or experiences. The decision to repair or replace made when you refer to the operation con-
dition and owner’s request.
Permitted clearance
q Parts used until the clearance between them increase to a certain limit. The limit at which those parts are used is “permitted
clearance".
q If the clearance between the parts exceeds the permitted clearance, they are repaired or replaced.
Permitted interference
q The permitted maximum interference between the hole and the shaft to be assembled is "permitted interference".
q The permitted interference shows the repair limit of the part of the smaller tolerance.
q Repair or replace the parts whose interferences are out of the approved limit.
HD465-8, HD605-8 00-77

STANDARD VAULE TIGHTEN TABLE 00 INDEX AND FOREWORD
STANDARD VAULE TIGHTEN TABLE

Table of tighten values for bolts and nuts
REMARK
Tighten the metric nuts and bolts to the value shown in the table below unless otherwise indicated.
Thread dimension
Width across hex (mm) Tighten value (Nm {kgm})
(mm)
10
6 11.8 to 14.7 {1.2 to 1.5}
(*2) 10
13
8 27 to 34 {2.8 to 3.5}
(*2) 12
17
10 59 to 74 {6 to 7.5}
(*1, *2) 14
19
12 98 to 123 {10 to 12.5}
(*1, *2) 17
14 22 153 to 190 {15.5 to 19.5}
24
16 235 to 285 {23.5 to 29.5}
(*1) 22
18 27 320 to 400 {33 to 41}
20 30 455 to 565 {46.5 to 58}
22 32 610 to 765 {62.5 to 78}
24 36 785 to 980 {80 to 100}
27 41 1150 to 1440 {118 to 147}
30 46 1520 to 1910 {155 to 195}
33 50 1960 to 2450 {200 to 250}
36 55 2450 to 3040 {250 to 310}
39 60 2890 to 3630 {295 to 370}
*1: Split flange bolt

*2: Flanged bolt
REMARK
Tighten flanged bolt identified with “7” on the head as shown in the tighten value shown in the table below.
00-78 HD465-8, HD605-8

00 INDEX AND FOREWORD STANDARD VAULE TIGHTEN TABLE
Thread dimension
Width across hex (mm) Tighten value (Nm {kgm})
(mm)
6 10 5.9 to 9.8 {0.6 to 1.0}
8 12 13.7 to 23.5 {1.4 to 2.4}
10 14 34.3 to 46.1 {3.5 to 4.7}
12 17 74.5 to 90.2 {7.6 to 9.2}
REMARK
Tighten the coarse thread bolts and nuts to the value shown in the table below unless otherwise indicated.
Type of bolt A B
Nominal dimension - Tighten value (Nm {kgm}) Tighten value (Nm {kgm})
threads per inch Range Target Range Target
1/ -20UNC 9.8 to 14.7 {1 to 1.5} 12.7 {1.3} 2.9 to 3.9 {0.3 to 0.4} 3.43 {0.35}
4
5/ 24.5 to 34.3 {2.5 to 3.5} 29.4 {3} 6.9 to 8.8 {0.7 to 0.9} 7.8 {0.8}
16-18UNC
3/ -16UNC 44.1 to 58.8 {4.5 to 6} 52.0 {5.3} 9.8 to 14.7 {1 to 1.5} 11.8 {1.2}
8
7/ 73.5 to 98.1 {7.5 to 10} 86.3 {8.8} 19.6 to 24.5 {2 to 2.5} 21.6 {2.2}
16-14UNC
1 108 to 147 {11 to 15} 127 {13} 29.4 to 39.2 {3 to 4} 34.3 {3.5}
/2-13UNC
9/ 157 to 216 {16 to 22} 186 {19} 44.1 to 58.8 {4.5 to 6} 51.0 {5.2}
16-12UNC
5/ -11UNC 226 to 294 {23 to 30} 265 {27} 63.7 to 83.4 {6.5 to 8.5} 68.6 {7}
8
3 392 to 530 {40 to 54} 461 {47} 108 to 147 {11 to 15} 127 {13}
/4-10UNC
7 637 to 853 {65 to 87} 745 {76} 177 to 235 {18 to 24} 206 {21}
/8-9UNC
HD465-8, HD605-8 00-79

Type of bolt A B
1-8UNC 883 to 1196 {90 to 122} 1040 {106} 245 to 333 {25 to 34} 284 {29}
11/8-7UNC 1187 to 1608 {121 to 164} 1393 {142} 333 to 451 {34 to 46} 392 {40}
11/4-7UNC 1598 to 2157 {163 to 220} 1873 {191} 451 to 608 {46 to 62} 530 {54}
11/2-6UNC 2354 to 3177 {240 to 324} 2765 {282} 657 to 892 {67 to 91} 775 {79}
REMARK
Tighten the fine thread bolts and nuts to the value shown in the table below unless otherwise indicated.
Type of bolt A B
1 14.7 to 19.6 {1.5 to 2} 17.7 {1.8} 3.9 to 4.9 {0.4 to 0.5} 4.41 {0.45}
/4-28UNF
5/ 34.3 to 39.2 {3.5 to 4} 34.3 {3.5} 7.8 to 9.8 {0.8 to 1} 8.8 {0.9}
16-24UNF
3/ -24UNF 53.9 to 68.6 {5.5 to 7} 61.8 {6.3} 14.7 to 19.6 {1.5 to 2} 16.7 {1.7}
8
7 83.4 to 108 {8.5 to 11} 96.1 {9.8} 24.5 to 29.4 {2.5 to 3} 26.5 {2.7}
/16-20UNF
1/ -20UNF 127 to 167 {13 to 17} 147 {15} 34.3 to 49.0 {3.5 to 5} 41.2 {4.2}
2
9/ 186 to 245 {19 to 25} 216 {22} 49.0 to 68.6 {5 to 7} 58.8 {6}
16-18UNF
5/ -18UNF 255 to 343 {26 to 35} 294 {30} 73.5 to 98.1 {7.5 to 10} 83.4 {8.5}
8
3/ -16UNF 441 to 598 {45 to 61} 520 {53} 127 to 167 {13 to 17} 147 {15}
4
7/ -14UNF 716 to 961 {73 to 98} 843 {86} 196 to 265 {20 to 27} 226 {23}
8
1-14UNF 1020 to 1373 {104 to 140} 1196 {122} 284 to 382 {29 to 39} 333 {34}
11/8-12UNF 1353 to 1844 {138 to 188} 1598 {163} 382 to 520 {39 to 53} 451 {46}
11/4-12UNF 1804 to 2432 {184 to 248} 2118 {216} 510 to 686 {52 to 70} 598 {61}
11/2-12UNF 2707 to 3658 {276 to 373} 3177 {324} 765 to 1030 {78 to 105} 892 {91}
00-80 HD465-8, HD605-8

Table of tighten value for o-ring boss piping joints

REMARK
Tighten the pipe joint of an o-ring boss to the value shown in the table below unless otherwise indicated.
Thread Tighten value (Nm {kgm})

Nominal Width across
dimension
number hex (mm) Range Target
(mm)
02 14 35 to 63 {3.5 to 6.5} 44 {4.5}
- 18 59 to 98 {6.0 to 10.0} 78 {8.0}
Varies
03, 04 20 depends on 84 to 132 {8.5 to 13.5} 103 {10.5}
05, 06 24 type of 128 to 186 {13.0 to 19.0} 157 {16.0}
connector.
10, 12 33 363 to 480 {37.0 to 49.0} 422 {43.0}
14 42 746 to 1010 {76.0 to 103} 883 {90.0}
Table of tighten value for o-ring boss plugs

REMARK
Tighten the plug for an o-ring boss to the value shown in the table below unless otherwise indicated.

dimension
(mm)
08 8 14 5.88 to 8.82 {0.6 to 0.9} 7.35 {0.75}
10 10 17 9.8 to 12.74 {1.0 to 1.3} 11.27 {1.15}
12 12 19 14.7 to 19.6 {1.5 to 2.0} 17.64 {1.8}
14 14 22 19.6 to 24.5 {2.0 to 2.5} 22.54 {2.3}
16 16 24 24.5 to 34.3 {2.5 to 3.5} 29.4 {3.0}
18 18 27 34.3 to 44.1 {3.5 to 4.5} 39.2 {4.0}
HD465-8, HD605-8 00-81


dimension
(mm)
20 20 30 44.1 to 53.9 {4.5 to 5.5} 49.0 {5.0}
24 24 32 58.8 to 78.4 {6.0 to 8.0} 68.6 {7.0}
30 30 32 93.1 to 122.5 {9.5 to 12.5} 107.8 {11.0}
33 33 - 107.8 to 147.0 {11.0 to 15.0} 127.4 {13.0}
36 36 36 127.4 to 176.4 {13.0 to 18.0} 151.9 {15.5}
42 42 - 181.3 to 240.1 {18.5 to 24.5} 210.7 {21.5}
52 52 - 274.4 to 367.5 {28.0 to 37.5} 323.4 {33.0}
Table of tighten value for hoses (Taper seal and face seal type)
REMARK
q Tighten the hose fittings (taper seal and face seal type) to the value shown in the table unless otherwise indicated.
q The table applies to the threads with a layer of engine oil.
Tighten value (Nm {kgm}) Taper seal Face seal

Nominal Width Nominal
number of across Thread Thread root
dimension -
hose hex (mm) Range Target dimension dimension
threads per
(mm) (mm)
inch
34 to 54 {3.5 to 5.5} 44 {4.5} - 9/ -18UN 14.3

16
02 19
34 to 63 {3.5 to 6.5} 44 {4.5} 14 - -
22 54 to 93 {5.5 to 9.5} 74 {7.5} - 11/ 17.5

16-16UN
03
24 59 to 98 {6.0 to 10.0} 78 {8.0} 18 - -
04 27 84 to 132 {8.5 to 13.5} 103 {10.5} 22 13 20.6

/16-16UN
05 32 128 to 186 {13.0 to 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 to 245 {18.0 to 25.0} 216 {22.0} 30 13/16-12UN 30.2
(10) 41 177 to 245 {18.0 to 25.0} 216 {22.0} 33 - -

(12) 46 197 to 294 {20.0 to 30.0} 245 {25.0} 36 - -
(14) 55 246 to 343 {25.0 to 35.0} 294 {30.0} 42 - -
00-82 HD465-8, HD605-8

Table of tighten value for face seal joints

REMARK
q The tighten value table below applies to the seal joint (sleeve nut type) metallic low-pressure piping which is used on en-
gine.
q The table applies to the threads with a layer of engine oil.
q Refer: The face seal joint and the dimension in ( ) is also part of the specification.
Outer Tighten value (Nm {kgm}) Face seal

Width
dimension of
across hex Nominal dimension Thread root
adequate Range Target
(mm) - threads per inch dimension (mm)
pipe (mm)
8 19 14 to 16 {1.4 to 1.6} 15 {1.5} 9 14.3

/16-18UN
10 22 24 to 27 {2.4 to 2.7} 25.5 {2.6} 11/ 17.5

16-16UN
12 24 (27) 43 to 47 {4.4 to 4.8} 45 {4.6} 13 20.6

/16-16UN
15 (16) 30 (32) 60 to 68 {6.1 to 6.8} 64 {6.5} 1-14UNS 25.4
22 (20) 36 90 to 95 {9.2 to 9.7} 92.5 {9.4} 13/16-12UN 30.2
Tighten value table for bolts and nuts on 102,107 and 114 engines
REMARK
Tighten the metric bolts and nuts used on the 102, 107 and 114 engines to the torques shown in the table unless otherwise
indicated.
Thread dimension (mm) Tighten value (Nm {kgm})

6 10±2 {1.02±0.20}
8 24±4 {2.45±0.41}
10 43±6 {4.38±0.61}
12 77±12 {7.85±1.22}
14 -
HD465-8, HD605-8 00-83

Tighten value table for 102, 107, and 114 engines (joint bolts)
REMARK
Tighten the metric joint bolts used on the 102, 107, and 114 engines to the value shown in the table unless otherwise indicated.
Thread dimension (mm) Tighten value (Nm {kgm})

6 8±2 {0.81±0.20}
8 10±2 {1.02±0.20}
10 12±2 {1.22±0.20}
12 24±4 {2.45±0.41}
14 36±5 {3.67±0.51}
Tighten value table for tapered screws on 102, 107, and 114 engines (NPT)
REMARK
Tighten the National pipe thread (NPT) screws used on the 102, 107, and 114 engines to the torques shown in the table unless
otherwise indicated.
Material of female screw In cast iron or steel In aluminum

Nominal thread dimension Tighten value (Nm {kgm}) Tighten value (Nm {kgm})
1/ 15±2 {1.53±0.20} 5±1 {0.51±0.10}
16
1/ 20±2 {2.04±0.20} 15±2 {1.53±0.20}

8
1/ 25±3 {2.55±0.31} 20±2 {2.04±0.20}

4
3/ 35±4 {3.57±0.41} 25±3 {2.55±0.31}

8
1/ 55±6 {5.61±0.61} 35±4 {3.57±0.41}

2
3 75±8 {7.65±0.82} 45±5 {4.59±0.51}

/4
00-84 HD465-8, HD605-8

00 INDEX AND FOREWORD CONVERSION TABLE
CONVERSION TABLE
Procedure for using the conversion table
The conversion table is provided to let simple conversion of the numerical numbers between the different units. For further de-
tails of the procedure of using the conversion table, see the examples given below.
Examples of using the conversion table to convert a unit from mm to in.

When you change 55 mm to in
1. Locate the number 50 in the left-most column, take this as (A), and then draw a horizontal line from (A).
2. Locate the number 5 in the top row, take this as (B), then draw a vertical line down from (B).
3. Take the point of the two lines as (C). This point (C) gives the value when you change the unit from mm to in. Thus, 55 mm
= 2.165 in.
When you change 550 mm to in
1. The number 550 does not appear in the table. Divide it by 10 (move the decimal point one position to the left) to get 55 mm.
2. Convert 55 mm to 2.165 in refer to the procedure.
3. The initial value (550 mm) was divided by 10. Multiply 2.165 in by 10 (move the decimal point one position to the right) to
repair the target value. This gives 550 mm = 21.65 in.
mm to in
(B)
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.017 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.780 3.819 3.858 3.898
mm to in
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
HD465-8, HD605-8 00-85

CONVERSION TABLE 00 INDEX AND FOREWORD
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
kg to lb
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
l to U.S.Gal
1l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
l to U.K.Gal
1l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
00-86 HD465-8, HD605-8

1l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to lbft
1 kgm = 7.233 lbft
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
HD465-8, HD605-8 00-87

1 kg/cm2 = 14.2233 lb/in2

0 1 2 3 4 5 6 7 8 9
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
Temperature
Convert Fahrenheit to Celsius
q A simple procedure to convert a Fahrenheit temperature indication into a Celsius temperature indication. See the numbers
in the middle of the table below. The figures in the middle of the table show the temperatures in the two Fahrenheit and
Celsius.
q When you change from Fahrenheit to Celsius degrees. Consider the middle of the table to be Fahrenheit temperatures and
read the corresponding Celsius temperature on the left.
q When you change from Celsius to Fahrenheit degrees. Consider the middle of the table to be Celsius values, and read the
corresponding Fahrenheit temperature on the right.
1 °C = 33.8 °F
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8
-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
00-88 HD465-8, HD605-8

1 °C = 33.8 °F
°C °F °C °F °C °F °C °F
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8
-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8
-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0
-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0
-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0
-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
HD465-8, HD605-8 00-89

00-90 HD465-8, HD605-8

01 SPECIFICATIONS
HD465-8, HD605-8 01-1

CONTENTS 01 SPECIFICATIONS
CONTENTS
ABBREVIATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-3
SPECIFICATIONS- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-8
DIAGRAM SPECIFICATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-8
DIAGRAM SPECIFICATION: HD465-8 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-8
DIAGRAM SPECIFICATION: HD605-8 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-10
SPECIFICATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-12
SPECIFICATIONS: HD465-8 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-12
SPECIFICATIONS: HD605-8 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-17
WEIGHT TABLE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-22
WEIGHT TABLE: HD465-8 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-22
WEIGHT TABLE: HD605-8 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-23
FUEL, COOLANT, AND LUBRICATING OIL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-24
01-2 HD465-8, HD605-8

01 SPECIFICATIONS ABBREVIATIONS
ABBREVIATIONS

and system)

System

Advanced Joystick
Automatic Retarder
Automatic Retarder
the operator.




CDR Engine

Closed-center Load
Sensing System


HD465-8, HD605-8 01-3

ABBREVIATIONS 01 SPECIFICATIONS

and system)

Electronic Control



Exhaust Gas
Recirculation



FOPS Cab and canopy
Structure

Global Positioning
System
Plus) location.

Global Navigation
Satellite System
Plus) location.

HSS

Hydro Static

Communication and
electronic control



01-4 HD465-8, HD605-8


and system)

KCCV Engine
filters.

KCSF Engine

KOMATSU Diesel
Oxidation Catalyst
muffler.

KDPF Engine
Particulate Filter
muffler.
KOMATSU Traction

such as a monitor.

LIN

load.
LVDS


Service
cell phones.

system
activated.

system
activated.
HD465-8, HD605-8 01-5

ABBREVIATIONS 01 SPECIFICATIONS

and system)

PCCS
transmission.

supply pump.

Hydraulic system
(D, PC, etc)
PTP

ROPS Cab and canopy
Structure
ISO 12117-2.

SCR Urea SCR system
of related devices.



Tip-Over Protective
Structure
overturning)

VGT Engine

Variable HorsePower
Control
of the machine.

D: Bulldozer
HD: Dump truck
WA: Wheel loader
01-6 HD465-8, HD605-8

A/C Air Conditioner
A/M Air Mix damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
ENG Engine
F.G. Frame Ground
GND Ground
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/M Transmission
HD465-8, HD605-8 01-7

DIAGRAM SPECIFICATION 01 SPECIFICATIONS
SPECIFICATIONS
DIAGRAM SPECIFICATION
DIAGRAM SPECIFICATION: HD465-8
Item Unit HD465-8

Gross weight (machine weight + max.
103500
payload + 1 operator (80 kg)
kg
Machine weight 48420
Max. payload 55000
Dump body capacity
Stacked 25
m3
Heaped (2:1) 34.2
Dump speed (raise)
(at engine speed of 2000 min-1 {2000 sec. 11.5
rpm})
Engine model - Komatsu SAA6D170E–7 diesel engine
Engine specified horsepower
q SAE J1995 (gross) (*1) 578 {775}/2000 {2000}
q ISO 14396 kW {HP}/min-1{rpm} 578 {775}/2000 {2000}
q ISO 9249/SAE J1349 (net) (*2) 540 {724}/2000 {2000}
A Complete length mm 10351
B Complete height mm 4400
Complete height when dump body is
C mm 8800
lifted
Complete width (from stay of right mirror
D mm 5543
to left mirror)
Minimum clearance (below machine
E mm 588
bottom)
Minimum turn radius mm 8730
01-8 HD465-8, HD605-8

01 SPECIFICATIONS DIAGRAM SPECIFICATION
Item Unit HD465-8

Travel speed
q Forward
1st 11.5
2nd 16.0
3rd 21.5
4th 29.5
km/h
5th 39.0
6th 52.5
7th 70.0
q Reverse
1st 12.0
Temperature range for operation °C -20 to 45
*1: Displays the value of the engine unit (without cooling fan).
REMARK
The engine horsepower specification is shown in the net value and gross value. Gross is the horsepower measured on the
basic engine unit. Net is the value measured of an engine in the same condition as when it is installed on a machine.
q Specified horsepower (net) at maximum cooling fan speed is the value that follows.
540 kW {724 HP}/2000 min-1{2000 rpm}
HD465-8, HD605-8 01-9

DIAGRAM SPECIFICATION 01 SPECIFICATIONS
DIAGRAM SPECIFICATION: HD605-8
Item Unit HD605-8

Gross weight (machine weight + max.
114700
payload + 1 operator (80 kg)
kg
Max. payload 63000
Dump body capacity
Stacked 29
m3
Heaped (2:1) 40
Dump speed (raise)
(at engine speed of 2000 min-1 {2000 sec. 11.5
rpm})
Engine model - Komatsu SAA6D170E–7 diesel engine
q SAE J1995 (gross) (*1) 578 {775}/2000 {2000}
q ISO 14396 kW {HP}/min-1{rpm} 578 {775}/2000 {2000}
q ISO 9249/SAE J1349 (net) (*2) 540 {724}/2000 {2000}
A Complete length mm 10351
B Complete height mm 4400
Complete height when dump body is
C mm 8800
lifted
Complete width (from stay of right mirror
D mm 5543
to left mirror)
Minimum clearance (below machine
E mm 588
bottom)
Minimum turn radius mm 8730
01-10 HD465-8, HD605-8

01 SPECIFICATIONS DIAGRAM SPECIFICATION
Item Unit HD605-8

Travel speed
q Forward
1st 11.4
2nd 15.8
3rd 21.3
4th 28.8
km/h
5th 38.8
6th 52.0
7th 70.0
q Reverse
1st 11.8
Temperature range for operation °C -20 to 45
REMARK
540 kW {724 HP}/2000 min-1{2000 rpm}
HD465-8, HD605-8 01-11

SPECIFICATIONS 01 SPECIFICATIONS
SPECIFICATIONS
SPECIFICATIONS: HD465-8
Item Unit HD465-8
Weight
Gross weight (machine weight + max. payload + 1 operator
kg 103500
(80 kg)
Front tire kg 25469
Rear tire 22951
Max. payload kg 55000
Weight distribution (At max. payload)
Front tire kg 35500
Rear tire 68000
Performance
Dump body capacity
Stacked 25
m3
Heaped (2:1) 34.2
Max. travel speed km/h 70
Gradeability (sin θ) % 24
Min. turn radius mm 8730
Dump angle (turn angle) deg. 48
Dimensions
Complete length mm 10351
Complete width (from stay of right mirror to left mirror) mm 5543
Complete height mm 4400
Body width mm 4603
Wheelbase mm 4300
Wheelbase (tread)
Front tire 3535
mm
Rear tire 3080
Complete tire width
Front tire 4255
mm
Rear tire 4595
Minimum clearance (below machine bottom) 588
Bottom of lifted dump body mm 560
Load height of dump body mm 3600
Dump body height (when dump body is lifted) mm 8800
Cab width mm 1576
01-12 HD465-8, HD605-8

01 SPECIFICATIONS SPECIFICATIONS
Item Unit HD465-8

Dump body length mm 6450
Engine
model - SAA6D170E–7
4-cycle, water-cooled, in-line, vertical, and
Type - direct injection type with turbocharger and
air-cooled aftercooler
No. of cylinders - bore x stroke mm 6 - 170 x 170
Total piston displacement l{cc} 23.15 {23150}
Performance
q SAE J1995 (gross) (*1) 578 {775}/2000 {2000}
q ISO 14396 kW {HP}/min-1{rpm} 578 {775}/2000 {2000}
q ISO 9249/SAE J1349 (net) (*2) 540 {724.1}/2000 {2000}
Max. torque (*2) Nm {kgm}/min-1 3724 {380}/1400 {1400}

{rpm}
Fuel consumption at specified horsepower g/kWh {g/HPh} 213 {159}
Starting motor - 24 V, 7.5 kW (2)
Alternator - 24 V, 90 A
Battery (*3) - 12 V, 200 Ah (2)
Radiator core type - CF79-4
Aftercooler core type - Corrugated aluminum
*2: Displays the value at the minimum cooling fan speed.
*3: The battery capacity (Ah) is indicated in the 5-hour rate.
REMARK
540 kW {724 HP}/2000 min-1{2000 rpm}
Power train
Torque converter
Type 3-element, 1-stage, 2-phase type
- Hydraulically actuated, wet-type, single-disc
Lockup clutch
clutch
Transmission
Torque flow type, counter-shaft type,
full-automatic type, electrically and
Type
- hydraulically operated type, and pump force
lubrication type
Number of speeds 7 forward and 2 reverse speeds
HD465-8, HD605-8 01-13

Item Unit HD465-8

Reduction gear system
Spiral bevel gear type, splash lubrication
Type
type
-
Reduction ratio 3.538
Differential type Straight bevel gear, splash lubrication type
Final reduction gear
Type Planetary gear, splash lubrication type
-
Steering system
Operating system - Full hydraulic
Suspension
Axle type
Front axle Independent type (MacPherson type)
-
Rear axle Full floating type
Suspension type
Hydro-pneumatic type (Automatic damping
Front axle
- force switching type)
Rear axle Hydro-pneumatic type
Tire
Size x quantity
Front tire 24.00R35AA x 2
-
Rear tire 24.00R35AA x 4
Inflation pressure
Front tire
kPa {kg/cm2} 680 to 700 {6.9 to 7.1}
Rear tire
Brake
Main brake
Dry type, single disc type
Front tire
Full hydraulic
-
Oil cooled multiple disc type
Rear tire
Full hydraulic
Parking brake -
Spring operated, hydraulic releasing type
Retarder -
Full hydraulic
01-14 HD465-8, HD605-8

Item Unit HD465-8

Hydraulic system
Steering and hoist control pump
Variable displacement swash plate piston
Type -
pump type
Discharged volume
When steering is operated
180.5 x 2
(at engine speed of 2000 min-1 {2000 rpm}) l{min}
When hoist is operated
180.5 x 2
(at engine speed of 2000 min-1 {2000 rpm})
Radiator fan pump
Type -
pump type
Discharged volume cm3/rev 63
Power train transmission pump

Type - Gear pump type
Discharged volume (at engine speed of 2000 min-1 l{min} 234

{2000 rpm})
Brake cooling pump
Discharged volume (at engine speed of 2000 min-1 l{min} 224 x 2

{2000 rpm})
Brake charge pump
Discharged volume (at engine speed of 2000 min-1 l{min} 57.9

{2000 rpm})
Secondary steering pump
Discharged volume l{min} 30.2
Cooling fan motor
Fixed displacement, swash plate, piston
Type -
type
Motor capacity cc/rev 90.3
Secondary steering motor
Type - DC motor type
Hoist cylinder
Type mm Double-acting piston type
Cylinder bore (1st) mm 185
Cylinder bore (2nd) mm 150
Piston rod diameter (1st) mm 170
Stroke mm 887
HD465-8, HD605-8 01-15

Item Unit HD465-8

Max. distance between pins mm 3161
Min. distance between pins mm 1367
Steering cylinder
2-stage piston type (double-acting piston
Type mm
type for second cylinder only)
Cylinder bore mm 85
Piston rod diameter mm 55
Stroke mm 410
Hydraulic tank - Enclosed box type
Hydraulic oil filter - Hydraulic tank return side
Hydraulic oil cooler - Air-cooled type
01-16 HD465-8, HD605-8

SPECIFICATIONS: HD605-8
Item Unit HD605-8
Weight
Gross weight (machine weight + max. payload + 1 operator
kg 114700
(80 kg)
Front tire kg 26068
Rear tire 25552
Max. payload kg 63000
Weight distribution (At max. payload)
Front tire kg 37622
Rear tire 77078
Performance
Dump body capacity
Stacked 29
m3
Heaped (2:1) 40
Max. travel speed km/h 70
Gradeability (sin θ) % 21
Min. turn radius mm 8730
Dump angle (turn angle) deg. 48
Dimensions
Complete length mm 10351
Complete width (from stay of right mirror to left mirror) mm 5543
Complete height mm 4400
Body width mm 4603
Wheelbase mm 4300
Wheelbase (tread)
Front tire 3535
mm
Rear tire 3080
Complete tire width
Front tire 4255
mm
Rear tire 4595
Minimum clearance (below machine bottom) 588
Bottom of lifted dump body mm 560
Load height of dump body mm 3600
Dump body height (when dump body is lifted) mm 8800
Cab width mm 1576
Dump body length mm 6450
HD465-8, HD605-8 01-17

Item Unit HD605-8
Engine
model - SAA6D170E–7
4-cycle, water-cooled, in-line, vertical, direct
Type - injection, with turbocharger and air-cooled
aftercooler
No. of cylinders - bore x stroke mm 6 - 170 x 170
Total piston displacement l{cc} 23.15 {23150}
Performance
SAE J1995 (gross) (*1) 578 {775}/2000 {2000}
ISO 14396 kW {HP}/min-1 578 {775}/2000 {2000}
{rpm}
ISO 9249/SAE J1349 (net) (*2) 540 {724.1}/2000 {2000}
Max. torque (*2) Nm {kgm}/min-1 3724 {380}/1400 {1400}

{rpm}
Fuel consumption at specified horsepower g/kWh {g/HPh} 213 {159}
Starting motor - 24 V, 7.5 kW (2)
Alternator - 24 V, 90 A
Battery (*3) - 12 V, 200 Ah (2)
Radiator core type - CF79-4
Aftercooler core type - Corrugated aluminum
*2: Displays the value at the minimum cooling fan speed.
*3: The battery capacity (Ah) is indicated in the 5-hour rate.
REMARK
540 kW {724 HP}/2000 min-1{2000 rpm}
Power train
Torque converter
Type 3-element, 1-stage, 2-phase type
- Hydraulically actuated, wet-type, single-disc
Lockup clutch
clutch
Transmission
Torque flow type, counter-shaft type,
full-automatic type, electrically and
Type
- hydraulically operated type, and pump force
lubrication type
Number of speeds 7 forward and 2 reverse speeds
01-18 HD465-8, HD605-8

Item Unit HD605-8

Reduction gear system
Spiral bevel gear type, splash lubrication
Type
type
-
Differential type Straight bevel gear, splash lubrication type
Final reduction gear
Type Planetary gear, splash lubrication type
-
Steering system
Operating system - Full hydraulic
Suspension
Axle type
Front axle Independent type (MacPherson type)
-
Rear axle Full floating type
Suspension type
Hydro-pneumatic type (Automatic damping
Front axle
- force switching type)
Rear axle Hydro-pneumatic type
Tire
Size x quantity
Front tire 24.00R35AA x 2
-
Rear tire 24.00R35AA x 4
Inflation pressure
Front tire
kPa {kg/cm2} 680 to 700 {6.9 to 7.1}
Rear tire
Brake
Main brake
Dry type, single disc type
Front tire
Full hydraulic
-
Rear tire
Full hydraulic
Parking brake -
Spring operated, hydraulic releasing type
Retarder -
Full hydraulic
HD465-8, HD605-8 01-19

Item Unit HD605-8

Hydraulic system
Steering and hoist control pump
Type -
pump type
Discharged volume
When steering is operated
180.5 x 2
(at engine speed of 2000 min-1 {2000 rpm}) l{min}
When hoist is operated
180.5 x 2
(at engine speed of 2000 min-1 {2000 rpm})
Radiator fan pump
Type -
pump type
Discharged volume cm3/rev 63
Power train transmission pump

Discharged volume (at engine speed of 2000 min-1 l{min} 234

{2000 rpm})
Brake cooling pump
Discharged volume (at engine speed of 2000 min-1 l{min} 224 x 2

{2000 rpm})
Brake charge pump
Discharged volume (at engine speed of 2000 min-1 l{min} 57.9

{2000 rpm})
Secondary steering pump
Discharged volume l{min} 30.2
Cooling fan motor
Fixed displacement, swash plate, piston
Type -
type
Motor capacity cc/rev 90.3
Secondary steering motor
Type - DC motor type
Hoist cylinder
Type mm Double-acting piston type
Cylinder bore (1st) mm 185
Cylinder bore (2nd) mm 150
Stroke mm 887
01-20 HD465-8, HD605-8

Item Unit HD605-8

Steering cylinder
2-stage piston type (double-acting piston
Type mm
type for second cylinder only)
Cylinder bore mm 85
Piston rod diameter mm 55
Stroke mm 410
Hydraulic tank - Enclosed box type
Hydraulic oil filter - Hydraulic tank return side
Hydraulic oil cooler - Air-cooled type
HD465-8, HD605-8 01-21

WEIGHT TABLE 01 SPECIFICATIONS
WEIGHT TABLE
WEIGHT TABLE: HD465-8
k This weight table is provided for your reference when you handle or transport the components.
k This weight table shows the dry weight.
Unit: kg
Machine model HD465-8
Serial number 30001 -
Engine assembly 3330
Output shaft assembly 141
Radiator assembly 463
Aftercooler (two in total) 45 (22 + 23)
Fuel tank 301
Torque converter 433
Transmission assembly 1308
Drive shaft assembly (Front) 47.8
Drive shaft assembly (Rear) 90.7
Rear axle assembly 6274
q Differential 819
q Final drive (one side) 1409
q Rear brake (one side) 721
Front axle (one side) 330
Front brake (one side) 142
Front suspension cylinder 499
Rear suspension cylinder 176
Frame 4830
Cab (platform) 1104
Operator's seat 63
Steering cylinder 45
Hoist cylinder 212
Demand valve 29
Orbitrol valve 19
Hoist valve 34
Radiator fan motor 35
Dump 10417
Power train and brake cooling duplex pump 21
Brake cooling, control triple pump 36
Radiator fan pump 51
Steering and hoist control pump 102
01-22 HD465-8, HD605-8

01 SPECIFICATIONS WEIGHT TABLE
WEIGHT TABLE: HD605-8

k This weight table is provided for your reference when you handle or transport the components.
k This weight table shows the dry weight.
Unit: kg
Serial number 30001 -
Engine assembly 3330
Output shaft assembly 141
Radiator assembly 463
Aftercooler (two in total) 45 (22 + 23)
Fuel tank 301
Torque converter 433
Transmission assembly 1308
Drive shaft assembly (Front) 47.8
Drive shaft assembly (Rear) 90.7
Rear axle assembly 6274
q Differential 819
q Final drive (one side) 1409
q Rear brake (one side) 721
Front axle (one side) 330
Front brake (one side) 142
Front suspension cylinder 499
Rear suspension cylinder 176
Frame 4830
Cab (platform) 1104
Operator's seat 63
Steering cylinder 45
Hoist cylinder 212
Demand valve 29
ORBITROL VALVE 19
Hoist valve 34
Radiator fan motor 35
Dump 13236
Power train and brake cooling duplex pump 21
Brake cooling, control triple pump 36
Radiator fan pump 51
Steering and hoist control pump 102
HD465-8, HD605-8 01-23

FUEL, COOLANT, AND LUBRICATING OIL 01 SPECIFICATIONS
FUEL, COOLANT, AND LUBRICATING OIL

USAGE OF FUEL, COOLANT, AND LUBRICATING OIL ACCORDING TO AMBIENT TEMPERATURE
Ambient temperature
Recommended Komatsu
Reservoir Fluid type °C °F
Fluids
Min. Max. Min. Max.
Engine oil for KDPF used in cold EOS5W30-LA

-25 35 -13 95
terrain (KES Diesel Engine Oil)
(Oil Change interval 250 hours) EOS5W40-LA
(Note.1) -25 40 -13 104
(KES Diesel Engine Oil)
Engine oil pan
EO10W30-LA
-20 40 -4 104
Engine oil for KDPF (KES Diesel Engine Oil)
(Oil Change interval 500 hours) EO15W40-LA
-15 50 5 122
(KES Diesel Engine Oil)
Transmission Case TO10 (KES) -30 10 -22 86

Power train oil (Note.2)
(incl. brake oil tank) TO30 (KES) 0 50 32 122
Power train oil TO10 (KES) -20 50 -4 122
HO46-HM (KES) -20 50 -4 122
Hydraulic Tank
Hydraulic oil HO-MVK (KES)
-30 50 -22 122
Front suspension
Hydraulic oil HO-MVK (KES) -30 50 -22 122
Rear suspension
Differential case
Power train oil TO30 (KES) -30 50 -22 122
Final drive case
G2-T (KES)
Hyper grease (Note.3) -20 50 -4 122
G2-TE (KES)
Grease fitting Lithium EP grease G2-LI (KES) -10 50 14 122

GL-LI-S (KES) -30 50 -22 122
Lithium grease
G2T2-LI -30 30 -22 86
Non-Amine Engine Coolant
Cooling system AF-NAC (KES) -30 50 -22 122
(AF-NAC) (Note.4)
ASTM D975 No.1–D S15 -30 20 -22 68
Fuel tank Diesel fuel
ASTM D975 No.2–D S15 0 50 32 122
ASTM: American Society of Testing and Material
Unit: l
Places to supply oil, coolant, etc. Specified capacity Refill capacity
Engine oil pan 97 80
Transmission case (including brake oil tank) 360 215
Hydraulic tank 250 149
Front suspension (each of right and left) 21.8 -
Rear suspension (each of right and left) 11.3 -
Differential case 95 95
Final drive case (each of right and left) 32 21
Fuel tank 825 -
01-24 HD465-8, HD605-8

01 SPECIFICATIONS FUEL, COOLANT, AND LUBRICATING OIL
Unit: l
Places to supply oil, coolant, etc. Specified capacity Refill capacity
Cooling system 213 204
REMARK
The specified capacity is the total oil quantity including the tanks and pipes. The refill capacity is the oil amount that is replaced
when checking and maintenance.
Note 1: Engine oil compatible with KDPF for cold climate deteriorates more easily than the engine oil compatible with the usual
KDPF (replace each 500 hours), replace the oil and filter cartridge each 250 hours. To change the maintenance time for the
machine monitor, please ask your KOMATSU distributor.
Note 2: The quality performance of power train oil and engine oil is different. Use the recommended oil for each.
Note 3: The hyper grease (G2-TE) is high-performance product.
When it is necessary to improve the quality of the lubricant to prevent pin noise, G2-T or G2-TE is recommended.
Note 4: Non-amine engine coolant (AF-NAC)
1. A coolant has important functions of freeze and corrosion protection.
Coolant usage is required in areas where freeze protection is not necessary.
The KES Non-Amine Engine Coolant (AF-NAC) is filled in Komatsu products.
Non-Amine Engine Coolant (AF-NAC) cools the system and provides corrosion and freeze protection. It is used continu-
ously for two years or 4000 hours.
Non-Amine Engine Coolant (AF-NAC) is recommended where it is available.
2. For the density of Non-Amine Engine Coolant (AF-NAC), follow the table below.
Coolant density table
°C Min. -10 -15 -20 -25 -30 -35 -40 -45 -50
Min. temperature
°F Min. 14 5 -4 -13 -22 -31 -40 -49 -58
Density (%) 30 36 41 46 50 54 58 61 64
HD465-8, HD605-8 01-25

FUEL, COOLANT, AND LUBRICATING OIL 01 SPECIFICATIONS
01-26 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION
HD465-8, HD605-8 10-1

CONTENTS 10 STRUCTURE AND FUNCTION
CONTENTS
ABBREVIATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-7
BOOT UP SYSTEM- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-12
BOOT UP SYSTEM DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-12
BOOT UP SYSTEM DIAGRAM (For machines equipped with emergency engine stop switch) - - - - - - - - - - - - 10-13
SYSTEM IN OPERATION LAMP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-15
OPERATION LAMP SYSTEM DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-15
FUNCTION OF OPERATION LAMP SYSTEM- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-15
BATTERY DISCONNECT SWITCH - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-16
BATTERY DISCONNECT SWITCH DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-16
FUNCTION OF BATTERY DISCONNECT SWITCH- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-17
ENGINE SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-20
ENGINE SYSTEM DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-20
FUNCTION OF ENGINE SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-21
ENGINE CONTROL SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-22
ENGINE CONTROL SYSTEM DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-22
AUTOMATIC IDLE STOP SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-26
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-26
ENGINE COMPONENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-28
OUTPUT SHAFT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-28
VGT- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-29
EGR SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-33
EGR VALVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-35
EGR COOLER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-37
KCCV SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-38
KCCV VENTILATOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-40
KDPF- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-42
COOLING SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-46
COOLING SYSTEM DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-46
SPECIFICATIONS OF COOLING SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-47
RADIATOR FAN CONTROL SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-48
RADIATOR FAN CONTROL SYSTEM DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-48
FUNCTION OF RADIATOR FAN CONTROL SYSTEM- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-48
COOLING SYSTEM COMPONENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-50
COOLING FAN PUMP- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-50
CONTROL SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-64
CONTROL SYSTEM DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-64
RETARDER AND HOIST CONTROL SYSTEM- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-65
RETARDER AND HOIST CONTROL SYSTEM DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-65
MACHINE MONITOR SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-67
MACHINE MONITOR SYSTEM DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-67
FUNCTION OF MACHINE MONITOR SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-68
REARVIEW MONITOR SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-69
REARVIEW MONITOR SYSTEM DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-69
FUNCTION OF REARVIEW MONITOR SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-69
KOMTRAX PLUS SYSTEM- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-70
KOMTRAX PLUS SYSTEM DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-70
FUNCTION OF KOMTRAX PLUS SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-72
PAYLOAD METER SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-75
PAYLOAD METER SYSTEM DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-75
10-2 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION CONTENTS
PAYLOAD METER SYSTEM DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-76

FUNCTION OF PAYLOAD METER SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-76
MEASUREMENT PRINCIPLE OF LOADING MASS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-77
MACHINE LOCK-OUT SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-86
LAYOUT DRAWING OF MACHINE LOCK-OUT SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-86
FUNCTION OF MACHINE LOCK-OUT SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-87
OPERATION OF MACHINE LOCK-OUT SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-87
CONTROL SYSTEM COMPONENTS- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-88
MACHINE MONITOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-88
SWITCH PANEL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-105
REARVIEW MONITOR- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-106
REARVIEW CAMERA - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-107
KOMTRAX TERMINAL- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-108
KOMTRAX PLUS CONTROLLER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-110
STRUCTURE OF KOMTRAX PLUS CONTROLLER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-110
INPUT AND OUTPUT SIGNALS OF KOMTRAX PLUS CONTROLLER - - - - - - - - - - - - - - - - - - - - - - - - - 10-110
WIRELESS LAN UNIT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-114
STRUCTURE OF WIRELESS LAN UNIT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-114
FUNCTION OF WIRELESS LAN UNIT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-114
INPUT AND OUTPUT SIGNALS OF WIRELESS LAN UNIT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-114
TRANSMISSION CONTROLLER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-115
RETARDER AND HOIST CONTROLLER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-119
MONITOR CONTROLLER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-123
ENGINE CONTROLLER- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-128
ABS CONTROLLER- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-140
ACCELERATOR PEDAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-144
GEAR SHIFT LEVER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-145
RETARDER CONTROL LEVER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-146
HYDRAULIC SYSTEM DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-147
HYDRAULIC SYSTEM COMPONENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-148
HYDRAULIC TANK - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-148
STEERING AND HOIST PUMP- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-149
LS VALVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-155
CO VALVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-156
POWER TRAIN AND BRAKE COOLING DUPLEX PUMP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-159
BRAKE COOLING, CONTROL TRIPLE PUMP- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-160
HOIST VALVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-162
POWER TRAIN SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-168
POWER TRAIN DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-168
TRANSMISSION CONTROL SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-169
TRANSMISSION CONTROL SYSTEM DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-169
GEAR SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFT RANGE - - - - - - - - - - - - - - - - - - - - - 10-171
GEAR SHIFT CONTROL SYSTEM- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-175
AUTOMATIC GEAR SHIFT CONTROL OF GEAR SHIFT CONTROL SYSTEM - - - - - - - - - - - - - - - - - - - 10-175
DIRECTION CONTROL SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-177
RIM PULL LIMIT FUNCTION FOR OVERLOAD PREVENTION OF DIRECTION CONTROL SYSTEM - - - 10-177
FUNCTION OF THROTTLE LIMIT FUNCTION AT F1 START AT D POSITION SETTING OF DIRECTION CON-
TROL SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-177
KOMATSU TRACTION CONTROL SYSTEM (KTCS)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-178
HD465-8, HD605-8 10-3

KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - 10-178

FUNCTION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS) - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-178
OPERATION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM LOGIC - - - - - - - - - - - - - 10-179
TRAVEL SPEED LIMITATION SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-180
SYSTEM DIAGRAM OF TRAVEL SPEED LIMITATION SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-180
FUNCTION OF TRAVEL SPEED LIMITATION SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-181
OPERATION OF TRAVEL SPEED LIMITATION SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-182
POWER TRAIN COMPONENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-184
DRIVE SHAFT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-184
TORQUE CONVERTER AND PTO- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-186
LOCKUP CLUTCH ECMV - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-190
TRANSMISSION- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-193
TRANSMISSION CONTROL VALVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-210
FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV - - - - - - - - - - - - - - - - - 10-212
AXLE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-221
DIFFERENTIAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-223
FINAL DRIVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-225
WORK EQUIPMENT SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-226
WORK EQUIPMENT CONTROL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-226
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-226
FUNCTION OF WORK EQUIPMENT CONTROL- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-226
HOIST CONTROL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-227
HOIST CONTROL SYSTEM DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-227
FUNCTION OF HOIST CONTROL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-227
WORK EQUIPMENT SYSTEM COMPONENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-229
DUMP LEVER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-229
HOIST EPC VALVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-234
STEERING SYSTEM- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-235
STEERING SYSTEM DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-235
STEERING SYSTEM FUNCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-236
STEERING COLUMN - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-237
STRUCTURE OF STEERING COLUMN - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-237
STEERING LINKAGE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-238
STRUCTURE OF STEERING LINKAGE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-238
STEERING SYSTEM COMPONENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-239
DEMAND VALVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-239
STEERING RELIEF VALVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-246
STRUCTURE OF STEERING RELIEF VALVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-246
FUNCTION OF STEERING RELIEF VALVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-246
OPERATION OF STEERING RELIEF VALVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-246
ORBITROL VALVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-247
STEERING PUMP SELECTOR SOLENOID VALVE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-253
CROSS-OVER RELIEF VALVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-254
SECONDARY STEERING PUMP- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-255
SECONDARY STEERING MOTOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-256
BRAKE SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-257
BRAKE SYSTEM DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-257
RETARDER CONTROL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-259
RETARDER CONTROL SYSTEM DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-259
FUNCTION OF RETARDER CONTROL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-259
10-4 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION CONTENTS
ARSC SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-260

ARCS SYSTEM DIAGRAM- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-260
FUNCTION OF ARSC SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-260
BRAKE SYSTEM COMPONENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-261
BRAKE CHARGE PUMP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-261
PARKING BRAKE SOLENOID VALVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-262
ACCUMULATOR CHARGE VALVE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-263
BRAKE CIRCUIT ACCUMULATOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-267
BRAKE VALVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-268
SECONDARY BRAKE VALVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-271
SECONDARY BRAKE RELAY VALVE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-272
PROPORTION PRESSURE REDUCING VALVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-273
SLACK ADJUSTER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-274
BRAKE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-276
PARKING BRAKE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-279
BRAKE SUB-TANK - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-281
ABS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-282
ABS SYSTEM DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-282
ABS SYSTEM DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-283
FUNCTION OF ABS- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-284
OPERATION OF ABS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-284
COMPONENT PARTS OF ABS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-287
AUTO-GREASING SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-290
FUNCTION OF AUTO-GREASING SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-293
COMPONENT PARTS OF AUTO-GREASING SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-294
AUTO-GREASING PUMP- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-294
AUTO-GREASING INJECTOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-295
SUSPENSION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-300
STRUCTURE OF SUSPENSION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-300
FUNCTION OF SUSPENSION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-300
FRONT SUSPENSION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-301
STRUCTURE OF FRONT SUSPENSION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-301
FUNCTION OF FRONT SUSPENSION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-302
REAR SUSPENSION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-303
STRUCTURE OF REAR SUSPENSION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-303
FUNCTION OF REAR SUSPENSION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-304
SUSPENSION CYLINDER- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-305
STRUCTURE OF SUSPENSION CYLINDER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-305
FUNCTION OF SUSPENSION CYLINDER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-305
OPERATION OF SUSPENSION CYLINDER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-305
WORK EQUIPMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-306
STRUCTURE OF WORK EQUIPMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-306
FUNCTION OF WORK EQUIPMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-306
CAB AND ATTACHMENTS- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-307
ROPS CAB- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-307
STRUCTURE OF ROPS CAB - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-307
FUNCTION OF ROPS CAB - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-307
HD465-8, HD605-8 10-5

CAB MOUNT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-308

STRUCTURE OF CAB MOUNT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-308
FUNCTION OF CAB MOUNT- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-308
10-6 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION ABBREVIATIONS
ABBREVIATIONS

and system)

System

Advanced Joystick
Automatic Retarder
Automatic Retarder
the operator.




CDR Engine

Closed-center Load
Sensing System


HD465-8, HD605-8 10-7

ABBREVIATIONS 10 STRUCTURE AND FUNCTION

and system)

Electronic Control



Exhaust Gas
Recirculation



FOPS Cab and canopy
Structure

Global Positioning
System
Plus) location.

Global Navigation
Satellite System
Plus) location.

HSS

Hydro Static

Communication and
electronic control



10-8 HD465-8, HD605-8


and system)

KCCV Engine
filters.

KCSF Engine

KOMATSU Diesel
Oxidation Catalyst
muffler.

KDPF Engine
Particulate Filter
muffler.
KOMATSU Traction

such as a monitor.

LIN

load.
LVDS


Service
cell phones.

system
activated.

system
activated.
HD465-8, HD605-8 10-9

ABBREVIATIONS 10 STRUCTURE AND FUNCTION

and system)

PCCS
transmission.

supply pump.

Hydraulic system
(D, PC, etc)
PTP

ROPS Cab and canopy
Structure
ISO 12117-2.

SCR Urea SCR system
of related devices.



Tip-Over Protective
Structure
overturning)

VGT Engine

Variable HorsePower
Control
of the machine.

D: Bulldozer
HD: Dump truck
WA: Wheel loader
10-10 HD465-8, HD605-8

A/C Air Conditioner
A/M Air Mix damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
ENG Engine
F.G. Frame Ground
GND Ground
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/M Transmission
HD465-8, HD605-8 10-11

BOOT UP SYSTEM DIAGRAM 10 STRUCTURE AND FUNCTION
BOOT UP SYSTEM
BOOT UP SYSTEM DIAGRAM
1: Monitor controller 8: Engine controller A

2: Retarder and hoist controller 9: Engine controller B
3: Transmission controller 10: Battery
4: Relay 11: Circuit breaker
5: Fuse box 12: System operation lamp
6: KOMTRAX Plus controller 13: Battery disconnect switch
7: KOMTRAX terminal 14: Engine shutdown secondary switch
10-12 HD465-8, HD605-8

BOOT UP SYSTEM DIAGRAM (For machines equipped with
10 STRUCTURE AND FUNCTION emergency engine stop switch)
BOOT UP SYSTEM DIAGRAM (For machines equipped with emer-

gency engine stop switch)
1: Monitor controller 5: Fuse box

2: Retarder and hoist controller 6: KOMTRAX Plus controller
3: Transmission controller 7: KOMTRAX terminal
4: Relay 8: Engine controller A
HD465-8, HD605-8 10-13

BOOT UP SYSTEM DIAGRAM (For machines equipped with
emergency engine stop switch) 10 STRUCTURE AND FUNCTION
9: Engine controller B 14: Engine shutdown secondary switch

10: Battery 15: Emergency engine stop switch
11: Circuit breaker 16: Emergency engine stop switch
12: System operation lamp 17: Emergency engine stop switch
13: Battery disconnect switch
10-14 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION SYSTEM IN OPERATION LAMP
SYSTEM IN OPERATION LAMP

OPERATION LAMP SYSTEM DIAGRAM
1: Battery disconnect switch 7: Engine controller

2: Battery 8: Transmission controller
3: Circuit breaker 9: Retarder and hoist controller
4: Fuse box 10: KOMTRAX terminal
5: System operation lamp 11: KOMTRAX Plus controller
6: Monitor controller
FUNCTION OF OPERATION LAMP SYSTEM
Examine the condition of each controller with the system operation lamp to prevent connection loss of the battery supply while
the controllers are in operation.
REMARK
q Before you shut off the battery supply, turn the start switch to the “OFF” position. Make sure that the system operation lamp
goes off, then turn the battery disconnect switch “OFF”.
q When the battery disconnect switch is turned “OFF” (the battery supply is OFF) while the system operation lamp is illumi-
nated, controller may lose data. Never operate the battery disconnect switch while the system operation lamp is illuminated.
q The system operation lamp goes off in 2 minutes after the start switch is turned to “OFF” position.
q The system operation lamp may illuminate while the start switch is in the off position. In this condition, KOMTRAX may
maintain its communication.
ON and OFF of system operation lamp

q 24 Volts is constantly applied to one side of system operation lamp (LED (Light emitting Diode)).
q When any controller is in operation, the controller side outputs Low (0 V), and a current flows through the diode and the
system operation lamp illuminates.
q When all controllers are stopped, the controller side outputs (24 V). Nothing flows through the diode and the system oper-
ation lamp goes off.
The system operation lamp may illuminate in the dark after it is turned off. It is because of electrical leakage and is not
unusual.
q When the start switch is in OFF position, KOMTRAX periodically starts and stops to maintain communication.
q The start and stop cycle (sleep cycle) of KOMTRAX varies because of the communication condition and machine stop time.
The lamp can illuminate as long as 1 hour.
When you turn off the battery circuit for maintenance but the system operation lamp is illuminated, turn the start switch to
ON once and then turn it OFF. The lamp goes off in 2 minutes.
HD465-8, HD605-8 10-15

BATTERY DISCONNECT SWITCH 10 STRUCTURE AND FUNCTION
BATTERY DISCONNECT SWITCH

BATTERY DISCONNECT SWITCH DIAGRAM
1: System operation lamp 2: Battery disconnect switch
10-16 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION BATTERY DISCONNECT SWITCH
FUNCTION OF BATTERY DISCONNECT SWITCH

(O): OFF position
(I): ON position
q The battery disconnect switch (1) is used as an alternative to re-
moval of the battery connection in the cases that follow.
q When the machine is in storage for a long period (1 month or
longer)
q When you service or repair the electrical system
q When you perform electric welding
q When you handle the battery
q When you replace the fuse, etc.
q When battery disconnect switch (1) is turned OFF (the switch is
opened), electrical supply for components, start switch B con-
nection and controllers is off. The condition is the same as the condition when the battery is not connected. All of the elec-
trical system of the machine will not operate.
NOTICE
q Do not turn OFF battery disconnect switch (1) while the system operating lamp is illuminated.
If the start switch is turned OFF and the lamp is illuminated, the controller is in operation and KOMTRAX continues
to communicate.
If battery disconnect switch (1) is turned OFF while the system operating lamp illuminates, it may cause controller
damage and data loss.
q Do not turn OFF battery disconnect switch (1) while the engine operates or immediately after the engine is
stopped.
If battery disconnect switch (1) is turned OFF while the alternator generates electricity, it will cause overvoltage in
the electrical system of the machine. This may cause serious damage to the electrical system, electrical devices
and controllers.
q Do not turn battery disconnect switch (1) to OFF position while the fan turns in reverse.
While fan is reversed, if the start switch is turned OFF, the fan reverse solenoid remains energized for a while to
protect the hydraulic motor.
Make sure that the fan stops completely before you turn the battery disconnect switch (1) to OFF.
REMARK
If battery disconnect switch (1) is turned OFF for a long period, the machine monitor and radio's clock will go back to the initial
setting. In this case, adjustment is required.
HD465-8, HD605-8 10-17

BATTERY DISCONNECT SWITCH 10 STRUCTURE AND FUNCTION
ENGINE SECONDARY SHUTDOWN SWITCH

ENGINE SECONDARY SHUTDOWN SWITCH DIAGRAM
1: Cover 2: Engine secondary shutdown switch

FUNCTION OF ENGINE SECONDARY SHUTDOWN SWITCH
The secondary shutdown switch for the engine is used when the engine does not stop when the start switch is turned to “OFF”
position.
NOTICE
q Do not use this switch except when there is an issue.
If an issue is found, consult your KOMATSU distributor for repair immediately.
q If this switch is set to the engine stop position while the machine operates correctly, “Engine Shutdown Secondary
SW in Operation” is shown on the machine monitor.
If “Engine Shutdown Secondary SW in Operation” is shown on the machine monitor, check that the switch cover
is closed and the switch is in “Normal” position.
If the switch is in “STOP ENGINE” position, turn it to “Normal” position.
10-18 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION BATTERY DISCONNECT SWITCH
OPERATION OF ENGINE SECONDARY SHUTDOWN SWITCH

1. Raise the cover (1).
2. Setting the secondary shutdown switch (2) for the engine to

upper position (a) operates the shutdown secondary function,
and stops the engine.
(a) STOP ENGINE: When abnormal (switch is at upper position)
(b) NORMAL: When normal (switch is at lower position)
REMARK
q When cover (1) is closed, shutdown secondary switch (2) for the
engine automatically goes back to the normal position (b).
q When the start switch is turned to “ON” position while shutdown
secondary switch (2) is in "STOP ENGINE" position (a), “Engine
Shutdown Secondary SW in Operation” is shown on the machine
monitor. If this screen is shown, return engine secondary shut-
down switch (2) to normal position (b).
HD465-8, HD605-8 10-19

ENGINE SYSTEM DIAGRAM 10 STRUCTURE AND FUNCTION
ENGINE SYSTEM
ENGINE SYSTEM DIAGRAM
1: Air cleaner 8: Engine oil filter

2: Start motor 9: Vibration damper
3: Damper 10: Alternator
4: KDPF-A 11: KCCV ventilator
5: KDPF-B 12: EGR cooler
6: Engine controller A 13: VGT
7: Engine controller B
REMARK
For the machine equipped with two systems of after treatment devices, the relationship between the part name of after treat-
ment devices and the engine controller failure code displayed on the machine monitor is shown below.
q When "-A" is at the end of the part name:
The failure code starts with "CA" and no fixed symbol is at the end of displayed failure.
Example)
Part name: KDPF differential pressure sensor-A
Failure code displayed on the machine monitor: CA1881
Failure displayed on the machine monitor: KDPF Differential Pressure Sensor Low Error
10-20 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION ENGINE SYSTEM DIAGRAM
q When "-B" is at the end of the part name:

The failure code starts with "CB" and "_2" is at the end of displayed failure.
Example)
Part name: KDPF differential pressure sensor-B
Failure code displayed on the machine monitor: CB1881
Failure code displayed on the machine monitor: KDPF Differential Pressure Sensor Low Error_2
FUNCTION OF ENGINE SYSTEM
q VGT (13) is a turbocharger which can change the pattern of the exhaust flow.
q EGR cooler (12) recirculates part of exhaust gas back to the combustion chamber to reduce temperature and control NOx
emissions.
q KDPF (4) and (5) are components used to purify the exhaust gas. KDOC (catalyst) and KCSF (filter to capture soot) are
part of it.
q KCCV ventilator (11) is a mechanism that causes the separation of oil in blowby gas and puts it in the intake side to be
burned in the engine. It is primarily made up of filters.
HD465-8, HD605-8 10-21

ENGINE CONTROL SYSTEM 10 STRUCTURE AND FUNCTION
ENGINE CONTROL SYSTEM

ENGINE CONTROL SYSTEM DIAGRAM
1: Battery disconnect switch 14: KOMTRAX terminal

2: Battery 15: Rearview monitor
3: Battery relay 16: Priming pump timer
4: Fuse box 17: Engine start relay
5: Start switch 18: Personal code relay
6: Fuse box 19: Engine start self-holding relay
7: Engine secondary shutdown switch 20: Alternator
8: KOMTRAX Plus controller 21: Start motor
9: Machine monitor 22: Accelerator pedal
10: Engine controller 23: Fuse
11: Transmission controller 24: Circuit breaker
12: Retarder and hoist controller 25: Battery disconnect switch (Optional)
13: Monitor controller 26: ABS controller (Optional)
10-22 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION ENGINE CONTROL SYSTEM
FUNCTION OF ENGINE CONTROL SYSTEM
q The neutral safety circuit is employed to secure safety engine start.

q The engine does not start when the gear shift lever is not in “N” (NEUTRAL) position.
q Engine secondary shutdown switch (7) is provided to stop the engine when start switch (5) does not stop the engine.
HD465-8, HD605-8 10-23

ENGINE CONTROL SYSTEM 10 STRUCTURE AND FUNCTION
OPERATION OF ENGINE CONTROL SYSTEM
Operation when start switch is turned to “ON” position

1. When, the start switch (5) is turned to “ON” position, terminals B and BR of the start switch are connected.
2. The battery relay posts are connected, and electricity flows from battery (2) through start switch (5) and coil of battery relay
(3) to ground.
3. As a result, power is supplied to each circuit of the machine.
4. At this time, ACC signal flows from the ACC post on the start switch (5) to the engine controller (10). The engine is the start
position.
Operation of neutral safety circuit

Electricity flows from the transmission controller (11) to the coil of engine start relay (18) when the gear shift lever is set in "N
(Neutral)" position.
Operation when start switch is turned to “START” position

1. When the start switch (5) is turned to “START”, electricity flows from start switch post C to the start motor. It runs through
engine start relay (18) and personal code relay (19), and the engine starts.
2. Engine start relay (18) does not operate and the engine does not start when the gear shift lever is not in "N (Neutral)" posi-
tion.
10-24 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION ENGINE CONTROL SYSTEM
Operation when start switch is turned to “OFF” position

1. When start switch (5) is turned to “OFF” position, ACC signal from start switch post ACC to engine controller (10) is shut off.
2. When the ACC signal is shut off, the engine decreases its speed and stops.
3. At the same time, alternator (21) stops, and the output from alternator post R is shut off.
4. The electricity from the start switch post BR is shut off.
5. The posts of battery relay (3) are opened. The electricity supplied to each circuit of the machine is shut off.
Operation when engine secondary shutdown switch is at “STOP ENGINE” position

1. If engine secondary shutdown switch (7) is turned to “STOP ENGINE” the electricity from start switch post ACC to engine
controller (10) is shut off.
2. Above induces the same condition as the time when start switch (5) is turned to “OFF” position, and the engine stops.
ENGINE AUTOMATIC WARM-UP FUNCTION
q This function increases engine rpm to warm the engine when the engine is started in a cold area.
q Engine speed at low idle increases to 1100 rpm when the engine coolant temperature is 60 °C or below at engine start.
q The condition required to increase the low idle speed depends on
the engine coolant temperature as shown in the figure.
q The engine speed becomes 750 rpm in the condition below, and
cancels the automatic warm-up function.
q The engine coolant temperature increases to 65 °C or higher
during the warm-up.
HD465-8, HD605-8 10-25

AUTOMATIC IDLE STOP SYSTEM 10 STRUCTURE AND FUNCTION
AUTOMATIC IDLE STOP SYSTEM

FUNCTION OF AUTOMATIC IDLE STOP SYSTEM
q When the auto idle stop function is on and the conditions for operation are satisfied, the engine stops after the set time.
q Auto idle stop system stops the engine when the controller judges the conditions are satisfied.
q The time of the auto idle stop function set in the user or service menu on the machine monitor.
Condition of automatic idle stop system operation

The auto idle stop function starts when all of these conditions are satisfied at the same time.
q Engine is in operation.
q Machine is stopped.
q Steering oil is not overheating (below 90 °C).
q Torque converter oil is not overheating (below 110 °C).
q Retarder oil is not overheating (below 110 °C).
q Battery volts normal.
q Dump body is against the stop.
q No float caution is generated.
q Engine automatic warm-up function is not in "Normal warm-up" mode.
q Gear shift lever is in NEUTRAL position.
q Hoist lever is in FLOAT position.
q Accelerator pedal is not depressed.
q Machine monitor is not set in service mode.
q No "lever input signal out of range" warning is generated.
q None of these failure codes are generated.
Corresponding failure codes are as follows.
Failure code Failure (Shown on screen)

DF10KB T/M Shift Lever Input Signal Short Circuit
DLT3KA T/M Output Speed Sensor Open Circuit
DGT1KX T/C Oil Temperature Sensor Input Signal Out of Range
DAQRKR CAN1 Defective Communication (T/M Controller)
DAQQKR CAN2 Defective Communication (T/M Controller)
DB1RKR CAN 1 Defective Communication (RHC)
DB1QKR CAN 2 Defective Communication (RHC)
D1EMKA Parking Brake Interlock Relay Output Open Circuit
D1EMKB Parking Brake Interlock Relay Output Ground Fault
D1EMKY Parking Brake Interlock Relay Output Hot Short Circuit
DW4BMA Parking Brake Valve Activity Malfunction
DW4BK4 Parking Brake Valve Release Trouble
Setting time
The set time for the auto idle stop function is set in the menus that follow.
For setting of each menu, see "TEST AND ADJUST".
10-26 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION AUTOMATIC IDLE STOP SYSTEM
Auto Idle Stop Timer Fixing (service menu)
Setting Contents of setting

In the menu to set the idle stop time, you can select OFF or the automatic idle stop setting of a maximum
Variable
of 60 minutes. (Default)
OFF The auto idle stop function does not operate, and the auto idle stop time setting menu is not displayed.
In the auto idle stop time setting menu, the operator can select the set time in the auto idle stop setting to
Set to "x" min.
"x" minutes (set time at left). (Cannot select OFF)
Auto Idle Stop Timer Fixing (user menu)
Setting Contents of setting

OFF Auto idle stop function does not operate. (Default)
Stop the engine "y" minutes (set time at left) after the conditions for operation of the auto idle stop system
"y" min.
are satisfied.
NOTICE
When you perform work with the Service menu, always examine the set value of the automatic idle stop.
HD465-8, HD605-8 10-27

ENGINE COMPONENTS 10 STRUCTURE AND FUNCTION
ENGINE COMPONENTS
OUTPUT SHAFT
STRUCTURE OF OUTPUT SHAFT
1: Outer body 5: Inner body

2: Flange 6: Rubber cushion (large)
3: Shaft 7: Rubber cushion (small)
4: Coupling 8: Cover
FUNCTION OF OUTPUT SHAFT
The output shaft is installed to the engine flywheel, and absorbs the torsional vibration caused by changes of the engine torque.
10-28 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION ENGINE COMPONENTS
VGT
VGT
Abbreviation for Variable Geometry Turbocharger
STRUCTURE OF VGT
REMARK
The shape is subject to machine models.
General view, section view
A: Exhaust outlet C: Intake air outlet

B: Exhaust inlet D: Intake air inlet
1: Turbine housing 7: Push rod
2: Hydraulic actuator 8: Nozzle ring
3: VGT speed sensor 9: Plate
4: Blower housing 10: Vane
5: Shaft 11: Turbine impeller
6: Blower impeller 12: Piston
HD465-8, HD605-8 10-29

FUNCTION OF VGT
C: Blower impeller T: Turbine impeller

1: Air cleaner 5: SCR assembly (*1)
2: VGT 6: EGR cooler
3: KDPF 7: EGR valve
4: AdBlue/DEF mixing tube (*1)
*1: This may not be installed on some machine models and specifications.
q The exhaust gas regulations are applied to the exhaust gas from engine operation at low speed, and at high speed. To
meet this, the EGR ratio is improved. (EGR ratio = Ratio of amount of EGR to amount of fresh suction air)
q To attain high EGR ratio, it is necessary that turbine inlet pressure (P3) is set higher than boost pressure (P2) (P3 > P2).
For this reason, the variable turbocharger (VGT) is employed, in which the exhaust gas pressure acting on turbine impeller
(T) is adjustable.
Also, since the boost pressure increases more quickly, generation of particulates caused by lack of oxygen during
low-speed operation (rotation) is reduced.
q The shaft attached to the turbine (T) operates the blower (C) and pushes air to the cylinder for combustion.
If VGT (2) sends more air, the fuel injection rate increases, thus the engine output is increased.
In addition, the air cooled by the aftercooler contains more oxygen thus the fuel injection rate increases result in increased
engine output.
NOTICE
Adequate quantity of clean high-quality oil is required to maintain VGT performance. Be sure to use Komatsu genuine
high quality oil. Follow the procedures in the Operation and Maintenance Manual when you replace oil or oil filter.
REMARK
It may sound like an air leak from the VGT or a boost pipe, but this is normal.
10-30 HD465-8, HD605-8

OPERATION OF VGT
1. The exhaust gas goes into (C) of turbine housing (4) and flows out through ports (P) and (D). Port (P) is surrounded by
plate (5) attached to turbine housing (4), nozzle ring (7), and vanes (6).
The area of its flow is changes when push rod (8) slides to the right or left.
2. Hydraulic actuator (3) moves piston (12) in the actuator up and down with the hydraulic pressure controlled by EPC valve.
It slides push rod (8) to the right and left.
3. The exhaust gas flows through vanes (6) and turns blower (10) through shaft (9) attached to turbine (11). As the result, the
blower impeller works as a compressor, the intake air enters through (A) is compressed and discharge through (B).
4. When exhaust gas pressure at inlet (C) of turbine housing (4) is low (engine speed in low range), push rod (8) slides left
and decreases (P).
5. The exhaust gas acts on turbine (11) and as turbocharger speed increases, more air (oxygen) is pushed in the engine.
VGT speed sensor (2) senses the rotation of the turbocharger.
When nozzle ring is "closed"

1. During low speed operation (rotation), exhaust gas inlet passage
(P) is narrow (L1). (It is not fully closed, however.)
2. If the pressure increases at the turbine while the nozzle ring is
closed, the turbine speed increases, and the turbocharger speed
increases.
HD465-8, HD605-8 10-31

When nozzle ring is "open"

1. During high-speed operation (rotation), exhaust gas inlet (P) is
wide (L2).
2. As the engine speed increases and the turbine inlet pressure
(exhaust gas pressure) increases, exhaust gas inlet (P) is
widened (L2). This allows the exhaust gas to act on turbine (11)
efficiently.
REMARK
q Nozzle ring (7), vanes (6), and push rod (8) are made in one unit,
and it slides only and does not rotate.
q Hydraulic actuator is equipped with VGT position sensor.
VGT position sensor is calibrated together with the variable mechanism of VGT and the result is written in the memory in
the VGT position sensor. Accordingly, if any of hydraulic actuator, VGT position sensor, and VGT unit fails, whole VGT must
be replaced.
Operation of hydraulic actuator

1. Hydraulic actuator (6) operates by the oil pressure controlled by
EPC valve (8).
2. Hydraulic pressure supplied by the engine boost oil pump (12) is
used for this function.
3. The position of hydraulic actuator (6) is sent to engine controller
by the signals from VGT position sensor (5).
10-32 HD465-8, HD605-8

EGR SYSTEM
EGR
Abbreviation for Exhaust Gas Recirculation
EGR SYSTEM DIAGRAM
REMARK
1: VGT 5: Intake connector

2: Intake manifold 6: EGR cooler
3: Mixing connector 7: Exhaust manifold
4: EGR valve
FUNCTION OF EGR SYSTEM
q EGR valve (hydraulically driven) (4) controls the gas flow from the exhaust section to the intake section.
Since the exhaust pressure is higher than the boost pressure, the exhaust gas flows to the intake section.
q EGR cooler (6) cools the exhaust gas.
Engine coolant is used to cool the exhaust gas.
q Connector (3) moves the air from the aftercooler and the exhaust gas from the EGR valve to the intake section.
q Exhaust gas is always clean with this system which controls the EGR circuit. It uses information sent from sensors installed
to each part to obtain EGR rate relative to the condition of operation. (EGR ratio means the ratio of EGR gas contained in
the intake gas.)
q Monitors EGR circuit to troubleshoot with sensors installed to each part to prevent a serious failure.
HD465-8, HD605-8 10-33

CIRCUIT DIAGRAM OF EGR SYSTEM
C: Blower impeller T: Turbine impeller

1: Air cleaner 11: Hydraulic actuator (power piston)
2: VGT 12: EPC valve (for EGR valve)
3: KDPF 13: EGR valve lift sensor
4: AdBlue/DEF mixing tube (*1) 14: Exhaust manifold
5: SCR assembly (*1) 15: Engine boost oil pump
6: Ambient pressure sensor 16: Intake manifold
7: Aftercooler 17: Charge (boost) pressure and temperature sensor
8: EGR cooler 18: Engine controller
9: EGR SYSTEM 19: Mixing connector
10: EGR valve
*1: This may not be installed on some machine models and specifications.
OPERATION OF EGR SYSTEM
1. The engine controller sends signals to open EGR valve (10) relative to the engine load. This provides clean exhaust gas
and low fuel consumption.
2. When EGR valve (10) opens, part of the exhaust gas (EGR gas) flows from exhaust manifold (14) into EGR cooler (8)
through the EGR pipes.
3. The EGR cooler (8) cools the exhaust gas, then it flows through EGR valve (10). It mixes with the supply air in connector
(19), and flows into the air intake manifold (16).
10-34 HD465-8, HD605-8

EGR VALVE
EGR
STRUCTURE OF EGR VALVE
REMARK
Section view
A: EGR gas inlet (from EGR cooler) C: Servo drive oil inlet
B: EGR gas outlet (to intake manifold) D: Servo drive oil outlet
1: Valve 5: Spring
2: Spring 6: EGR valve lift sensor
3: Power piston 7: EPC valve (for EGR)
4: Spool
Structure
q EGR valve consists of the EGR gas flow control mechanism and EPC valve.
q EPC valve (1 pieces) is installed to control EGR valve.
REMARK
EPC valve that controls the VGT is installed to the bottom of front exhaust manifold at the right side of engine.
HD465-8, HD605-8 10-35

OPERATION OF EGR VALVE

1. The oil from the boost oil pump flows in port (C) of EGR valve.
The control pressure from EPC valve goes into port (E).
2. Spool (4) is moved to the right by the reaction force of spring (5),
and the effect of spring (2) closes valve (1). Accordingly, the
exhaust gas from EGR cooler does not flow to the intake side.
3. To open valve (1), the control pressure from EPC valve enters
port (E) first. The position of spool (4) is determined by the
balance of the control pressure and spring (5).
4. Since the hydraulic circuit of power piston (3) opens, the oil from
the engine boost oil pump flows through port (C) and pushes
power piston (3) to the left.
5. The oil from the boost oil pump acts on power piston (3) and
generates force (Fp).
6. When force (Fp) increases more than reaction force (Fs) of spring (2), valve (1) opens and the exhaust gas flows to the
intake side.
7. The hydraulic circuit to spool (4) closes by movement of power piston (3), power piston (3) is stopped at a position deter-
mined by spool (4).
8. The engine controller controls the valve position by controlling the spool position with the control pressure of EPC valve.
9. Since the servo mechanism is applied, external force applied to valve (1) does not act on spool (4) which contacts power
piston (3).
10. EGR valve lift sensor senses the displacement of spool (4).
10-36 HD465-8, HD605-8

EGR COOLER
EGR
STRUCTURE OF EGR COOLER
REMARK
A: EGR gas inlet D: Coolant outlet

B: EGR gas outlet (to EGR valve) E: Air vent
C: Coolant inlet F: Air vent
1: Header plate 3: Inner fin
2: Flat tube 4: Case
OPERATION OF EGR COOLER
1. EGR gas enters through (A) and flows through flat tubes (2) (9 pieces).
2. Coolant goes through (C), flows around flat tubes (2) in case (4), and goes out through (D).
3. Flat tube (2) has inner fins (3), thus EGR gas cools satisfactorily and is discharged through EGR gas outlet (B).
HD465-8, HD605-8 10-37

KCCV SYSTEM
KCCV
Abbreviation for KOMATSU Closed Crankcase Ventilation
KCCV SYSTEM DIAGRAM
REMARK
A: Blowby gas C: Removed engine oil (to engine oil pan)

B: Blowby gas from which engine oil is removed (to VGT)
1: VGT 3: KCCV ventilator
2: CDR valve 4: Check valve
FUNCTION OF KCCV SYSTEM

q In the past, blow by gas (A) was allowed to be released into the air, but now it is not permitted because of emission regu-
lations.
q Blowby gas (A) contains parts of the engine oil. A filter is installed to KCCV ventilator (1) to remove the engine oil to prevent
these possible problems if it is recirculated to VGT (2) as it is.
q Deterioration of turbocharger and aftercooler performance caused by tacky engine oil.
q Abnormal combustion in engine
q Malfunction of each sensor caused by tacky engine oil.
10-38 HD465-8, HD605-8

OPERATION OF KCCV SYSTEM

Diagram on the left shows the standard flow of blowby gas. Diagram on the right shows the flow of blowbygas which is pulled
in through the KCCV and recirculated.
A: Blowby gas Engine oil

B: Clean gas
1: Air cleaner 5: Breather
2: Turbocharger 6: KCCV ventilator
3: Aftercooler 7: Engine oil pan
4: Cylinder block (crankcase)
1. This system removes engine oil (C) from blowby gas (A) in cylinder block (4). It uses the filter in KCCV (6), and recirculates
clean gas (B) to the air intake side of VGT (2).
2. The removed engine oil (C) is drained to the engine oil pan (7) through the check valve.
HD465-8, HD605-8 10-39

KCCV VENTILATOR
KCCV
Abbreviation for KOMATSU Closed Crankcase Ventilation
STRUCTURE OF KCCV VENTILATOR
REMARK
A: Blowby gas inlet (engine breather) D: Coolant inlet

B: Blowby gas outlet (to VGT intake side) E: Coolant outlet
C: Oil drain port (to engine oil pan)
1: Heater tube 5: Filter
2: Crankshaft case pressure sensor 6: Relief valve
3: Case 7: Impactor
4: CDR valve
Structure
q There are two types of filters (5). One is the top load type, and the other is the bottom load type.
q The top load type (removed from the top) and bottom load type (removed from the bottom) are different from each other in
the position of the Crankshaft case pressure sensor.
In the top load type (removed from the top), the crankshaft case pressure sensor is installed to the blowby gas inlet piping.
In the bottom load type (removed from the bottom), the crankshaft case pressure sensor is installed to the top of KCCV
ventilator.
10-40 HD465-8, HD605-8

FUNCTION OF KCCV VENTILATOR

q If the blowby gas goes to the intake side of VGT and crankshaft case pressure becomes negative, the crankshaft seal may
allow dust into the engine.
The CDR valve (4) controls crankcase pressure to prevent this issue.
q Crankshaft case pressure may increases and oil leakage may occur if filter (5) of KCCV is clogged.
Thus, crankshaft case pressure sensor detects filter clogs (5).
q Keep KCCV warm with warmed-up engine coolant, to prevent the blowby gas passage from a frozen clog.
q Relief valve (6) is in case (3), and operates to bypass the blowby gas and protect KCCV and the engine when filter (5) is
blocked.
OPERATION OF KCCV VENTILATOR
1. Blowby gas goes into inlet (A) and moves through impactor (7) in filter (5), where it filters large particles in the oil spray.
2. Filter (5) disconnects particles in the oil spray.
3. The removed oil flows out from the bottom of filter (5), and to oil drain port (C), and then drains to the engine oil pan.
4. The crankcase pressure sensor (2) senses the crankcase pressure (blowby gas pressure). If the engine controller senses
the value of crankcase pressure sensor (2) that filter (5) is clogged, it shows failure code CA555. If the pressure increases
further, it shows failure code CA556.
5. Relief valve (6) is installed in case (3) and operates when filter (5) is blocked.
6. CDR valve (4) operates when the crankcase pressure becomes negative, and prevents.
CDR VALVE
CDR
Abbreviation for Crankcase Depression Regulator
OPERATION OF CDR VALVE
1. Spring (2) pushes up diaphragm (1), and blowby gas flows from
crankcase side (A) to turbocharger side (air intake side) (B).
2. As the intake air at turbocharger side (air intake side) (B)
increases, pressure on crankcase side (P1) decreases.
3. Ambient pressure (P2) exceeds the force of spring (2).
Diaphragm (1) shuts and temporarily blocks the flow.
4. When blowby gas accumulates in the crankcase, pressure (P1)
on crankcase side increases, and pushes up diaphragm (1)
again and blowby gas starts to flow.
HD465-8, HD605-8 10-41

KDPF
KDPF
Abbreviation for KOMATSU Diesel Particulate Filter
STRUCTURE OF KDPF
REMARK
General view
A: From VGT B: To exhaust pipe

1: Inlet unit 8: KDPF differential pressure sensor port
2: KDOC inlet temperature sensor 9: KDPF differential pressure sensor
3: KDOC unit 10: KDPF differential pressure sensor port
4: KCSF unit 11: KDOC outlet temperature sensor
5: Temperature sensor controller 12: Sensor bracket
6: Outlet unit 13: Hanger bracket
7: KDPF outlet temperature sensor 14: Sensor bracket band
Structure
q KDPF has inlet unit (1) to introduce the exhaust gas, KDOC unit (3) to contain the oxidation catalyst, KCSF unit (4) to con-
tain the soot filter equipped with catalyst, and unit (6) to release the exhaust gas.
q KDOC unit (3) has a ceramic honeycomb equipped with the oxidation catalyst.
q The ceramic honeycomb is protected with a special fiber mat to prevent ceramic breakage during engine and body vibra-
tions.
The mat also insulates the KDPF from the ceramics which goes high temperature during operation.
10-42 HD465-8, HD605-8

q KCSF unit (4) has ceramic honeycomb equipped with the oxidation catalyst, similar to KDOC unit (3).
The inner piece of the KCSF unit (4) has many cells using ceramic for separation. The cells are arranged in block patterns,
the inlet side arranged alternate to the outlet side.
q KDPF is equipped with KDPF temperature sensor (assembly of KDOC inlet temperature sensor, KDOC outlet temperature
sensor, and KDPF outlet temperature sensor). It includes the differential pressure sensor (assembly of KDPF differential
pressure sensor and KDPF outlet pressure sensor).
Combination of temperatures sensed by these 3 temperature sensors is used to monitor the functions of KCSF unit (4) and
KDOC unit (3). They also troubleshoot different components.
q The differential pressure sensor monitors accumulation of soot in KCSF unit (4). It senses the pressure difference between
the two sides of KCSF unit (4), and uses the data for troubleshooting of different components, similar to the temperature
sensor.
FUNCTION OF KDPF
A: Flow of exhaust gas
1: KDOC (oxidation catalyst)
2: KCSF
3: Seal (ceramic made)
4: Cell
5: Ceramics honeycomb
q KDPF purifies the exhaust gas by catching large quantity of soot
or PM (Particulate Matter) which is contained in the engine ex-
haust gas.
q KDOC (oxidation catalyst) (1) oxidizes NO (nitrogen monoxide)
contained in the exhaust gas into NO2(nitrogen dioxide), and re-
generates (*1) KCSF (2).
*1: Soot purification (oxidation) treatment
q KCSF (2) captures soot.
q Accumulated soot in KCSF (2) in operation range where the tem-
perature of exhaust gas is relatively high is naturally oxidized. It
is burnt away by the effect of KDOC (oxidation catalyst) (1). (This
is called passive regeneration)
REMARK
Passive regeneration is not performed when light load operation
and low temperature condition of the exhaust gas continue. Ac-
cumulated soot is gradually increased.
q Engine controller always monitors 2 soot accumulation values
and compares them. One is calculated from the condition of engine operation, the other is calculated from the differential
pressure sensor which is attached to KCSF (2).
q If the quantity of soot and exhaust gas temperature exceed the specified level, engine controller performs automatic regen-
eration to burn the soot. While performing automatic regeneration, the engine controller calculates the exhaust gas tem-
perature at KDOC inlet and exhaust gas volume, and controls the engine to raise the temperature of engine exhaust gas.
(This is called exhaust gas temperature raise control)
The fuel quantity injected from the fuel doser installed at the turbocharger outlet controls the temperature of the engine
exhaust at the KDOC inlet. The VGT controls the exhaust gas volume.
The engine controller enhances the oxidation power in KDOC (1). It increases the temperature of engine exhaust gas au-
tomatically, and improves combustion of soot caught in KCSF (2).
REMARK
When regeneration on the machine monitor is disabled, external air temperature is very low, or during operation at contin-
uous light load, exhaust temperatures remain low. In these conditions, automatic regeneration is not performed and the
quantity of soot accumulation increases.
HD465-8, HD605-8 10-43

q If automatic regeneration is not performed because of the excess quantity of accumulated soot in KCSF (2), perform man-
ual stationary regeneration. This will burn the soot and reduce the quantity of soot inside KCSF (2).
REMARK
Too much soot interferes with the flow of exhaust gas which increases fuel consumption and affects efficient engine com-
bustion. It may lead to other failures.
If the quantity of soot increases further, you cannot safely perform manual stationary regeneration. This will result in a KDPF
failure and replacement is unavoidable. Make sure to follow the procedures in the Operation and Maintenance Manual
when performing manual stationary regeneration.
TYPES OF REGENERATION FUNCTIONS
Regeneration is to purify (oxidize) the soot accumulated on the soot collection filter (KCSF) in KDPF or maintain the urea SCR
system as normal.
Passive regeneration
At high exhaust temperatures, oxidation of soot in the exhaust components increases because of the catalysts of KDOC burn
the soot accumulated in KCSF naturally.
In operation regeneration (engine exhaust temperature rise control + fuel dosing)

q Automatic regeneration
q The engine goes into exhaust temperature rise control mode (*1) when soot accumulates above a certain level. Re-
quest from the Urea SCR system to maintain normal function will activate the exhaust temperature rise control mode
also. The mode control will perform fuel dosing (*2) and start automatic regeneration.
The automatic regeneration is directed by the engine controller at a set time after the previous regeneration, regardless
of soot accumulation in KCSF.
*1: Control to increase the engine exhaust temperature by fuel injection timing or VGT.
*2: Fuel injection performed to accelerate regeneration by increase of the exhaust temperature.
q Manual stationary regeneration
q When the exhaust temperature does not achieve a certain level, or when regeneration is disabled, automatic regener-
ation is not performed. Accumulated soot increases in the KCSF. When the urea SCR system requests automatic, the
exhaust temperature may not achieve a certain level. In these cases, a request for manual stationary regeneration is
shown on the monitor, and the operator must start regeneration from the monitor screen.
When the engine controller is replaced or ash in KCSF is cleaned, a technician performs regeneration by the operation
on the machine monitor screen (Active Regeneration for Service).
NOTICE
q For the procedure to start and stop KDPF regeneration, see the Operation and Maintenance Manual for each ma-
chine.
q Always use ultra-low-sulfur diesel fuel. If any fuel other than the specified one is used, it can cause a failure in
KDPF.
q Always use specified Komatsu genuine engine oil applicable to KDPF. If any oil other than the specified one is
used, it can clog KDPF quickly, and that can increase fuel consumption and cause a failure in KDPF.
q Do not modify KDPF body and exhaust pipe. If modification is made, KDPF cannot operate normally and may have
trouble.
q Do not stand on, drop hit or cause other damage to the KDPF. KDPF has ceramic parts in it, and they may be bro-
ken by a strong impact.
q When a small quantity of soot is accumulated, the engine controller may start automatic regeneration. This auto-
matic regeneration is to maintain normal function of KDPF or urea SCR system, and is not a defect. Automatic
regeneration to maintain the function of urea SCR system normal or manual stationary regeneration takes approx-
imately 1 hour.
q During the automatic regeneration and the manual stationary regeneration, VGT operates automatically and the
engine sound changes. Also, the exhaust gas flow rate in KDPF changes, and the exhaust sound changes. This is
normal operation.
10-44 HD465-8, HD605-8

q During automatic and manual stationary regeneration, especially at low temperature, white smoke is released
through the exhaust pipe for a short time. This is normal operation. Be sure to perform regeneration in a well-ven-
tilated area, since carbon monoxide is generated.
q During automatic and manual stationary regeneration, the exhaust pipe may smell different from usual. This is nor-
mal operation.
q During the automatic regeneration and the manual stationary regeneration, the temperature of the exhaust gas dis-
charged from the exhaust pipe may increase above 650. To prevent a fire, make sure there is nothing flammable
around the exhaust pipe. Make sure the area around the machine is safe, and there is no person in the exhaust
gas area.
q KDPF has a dry operation function to prevent accumulation of fuel in the KDPF when the machine operates for a
long period of time at low hours. During this function, the engine controller increases the engine exhaust temper-
ature automatically and performs dry operation of the KCSF, when the set condition is satisfied. When the auto-
matic dry operation is not sufficient to complete the operation, manual stationary regeneration is required.
q The standard temperature of KDPF is shown below.
KDOC In (KDOC inlet KDOC Out (KDOC outlet KDPF Out (KDPF outlet
temperature sensor) temperature sensor) temperature sensor)
While regeneration is not performed
100 to 250 °C
(idling condition)
While regeneration is performed
100 to 250 °C 400 to 550 °C
(thermal mode: 1000)
HD465-8, HD605-8 10-45

COOLING SYSTEM DIAGRAM 10 STRUCTURE AND FUNCTION
COOLING SYSTEM
COOLING SYSTEM DIAGRAM
1: Pressure valve cap 8: Oil cooler outlet hose

2: Aftercooler inlet hose 9: Fan
3: Radiator inlet hose (from engine) 10: Aftercooler outlet hose
4: Cooling fan motor 11: Radiator
5: Bypass hose (from engine: at a low temperature) 12: Lower tank (a power train and a break cooling oil cooler
6: Radiator outlet hose (to engine) are integrated)
7: Oil cooler inlet hose 13: Aftercooler A
10-46 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION COOLING SYSTEM DIAGRAM
14: Aftercooler B 17: Upper tank

15: Sub-tank 18: Work equipment air cooler
16: Reserve tank 19: Air conditioner condenser
SPECIFICATIONS OF COOLING SYSTEM
Radiator
Core type: CF79-4
Relief pressure of pressure valve: 90±15 kPa {0.9±0.15 kg/cm2}
Torque converter oil cooler

Core type: PTO-OL
Steering oil cooler

Core type: CF40-1
HD465-8, HD605-8 10-47

RADIATOR FAN CONTROL SYSTEM 10 STRUCTURE AND FUNCTION
RADIATOR FAN CONTROL SYSTEM

RADIATOR FAN CONTROL SYSTEM DIAGRAM
FUNCTION OF RADIATOR FAN CONTROL SYSTEM

q The transmission controller monitors the temperatures of the coolant, transmission, engine oil, hydraulic oil, brake oil, en-
gine intake pressure, and external air. These temperatures are used to control the fan speed.
Fan speed control

q The transmission controller outputs the maximum value of the fan target speeds obtained from the temperatures of the cool-
ant, transmission lubricating oil, hydraulic oil, brake oil, and engine boost. The pump control signals to the cooling fan pump.
q The cooling fan pump changes the swash plate angle to control the released volume of oil to be sent to the cooling fan
motor.
q When the ambient temperature is low, a small volume of oil is sent to the fan motor to decrease fan speed to prevent an
over cool condition.
Selection of fan rotation mode

When the start switch is ON and the engine stopped, select the fan reverse mode in the monitor menu to reverse the fan. There
are two fan rotation modes, one is the normal mode and the other is the reverse mode. The transmission controller operates
the reverse solenoid valve of the cooling fan motor to change the fan rotation direction, relative to the selected mode.
q Normal rotation mode
The reverse solenoid valve does not operate and the fan turns normally, its speed varies relative to the temperature sensor
signal.
q Reverse rotation mode
The fan turns in reverse at high speed to blow off dust on the after cooler fan regardless of the temperature sensor signals.
The cleaning interval of the after cooler fan can be lengthened by using this mode periodically.
10-48 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION RADIATOR FAN CONTROL SYSTEM
Interlock when mode is changed

q When fan rotation direction is changed during fan operation, it will cause damage to the fan operation circuit.
q When the Radiator fan reverse mode is selected in the user menu of the machine monitor while the engine operates, the
signal is ignored. The message "Fan rotation direction cannot be changed" is shown on the machine monitor and the fan
does not reverse to protect the operation circuit.
Engine net horsepower constant control

This keeps net horsepower constant. Regardless of the hydraulic fan condition by correction of the engine output correspond-
ing to the horsepower consumed by the hydraulic fan.
HD465-8, HD605-8 10-49

COOLING SYSTEM COMPONENTS 10 STRUCTURE AND FUNCTION
COOLING SYSTEM COMPONENTS

COOLING FAN PUMP
STRUCTURE OF COOLING FAN PUMP
General view
10-50 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION COOLING SYSTEM COMPONENTS
P: EPC valve pressure port PS: Pump suction port

P1: Pump release port Pd: Drain port
PAEPC: EPC output pressure plug Pd3: Drain port
1: Servo valve 3: EPC valve
2: Air bleed
Section view
1: Shaft 7: Cylinder block

2: Servo piston 8: Valve plate
3: Spring 9: Case
4: Rocker cam 10: Oil seal
5: Shoe 11: Ball retainer
6: Piston
HD465-8, HD605-8 10-51

Structure
q Cylinder block (7) is held on shaft (1) by spline (11). Shaft (1) held by the front and rear bearings (12).
q The point of piston (6) has a spherical shape and is attached to shoe (5). Piston (6) and shoe (5) make a spherical bearing.
q Rocker (4) has a flat surface (A) and shoe (5) is always pushed against this surface while it slides in a circular pattern.
q Rocker (4) slides and pivots on ball (13).
q Piston (6) moves in relation to the axial direction in each cylinder of cylinder block (7).
q Cylinder block (7) turns in relation to valve plate (8) while it blocks pressurized oil and correctly balances oil pressure on
this level.
q The pressurized oil is forced in and released from each cylinder in the block (7) through valve plate (8).
SPECIFICATIONS OF COOLING FAN PUMP
Model: LPV90 (63)
Type: Variable displacement swash plate type piston pump
Theoretical discharged volume: 63 cm3/rev
Fan drive pressure: 17.3 MPa {177 kg/cm2}
Rated speed: 2374 rpm
FUNCTION OF COOLING FAN PUMP
q This pump converts rotation of the engine and transmits it by shaft into hydraulic pressure and discharges pressurized oil
corresponding to the load.
q It is possible to change the discharge volume by a change of the swash plate angle.
10-52 HD465-8, HD605-8

OPERATION OF COOLING FAN PUMP

1. Cylinder block (7) turns together with shaft (1) and shoe (5) slides
on surface (A).
2. Rocker (4) pivots on ball keeper (11), and angle (a) between
middle lines (X) of rocker (4) as the axial direction of cylinder
block (7) changes.
3. Angle (a) is specified as swash plate angle.
4. While angle (a) is made between middle of line (X) of the rocker
(4) and the axial of cylinder block (7), flat surface (A) work as a
cam for shoe (5).
5. Piston (6) slides in cylinder block (7) and a difference is made
between volumes (E) and (F) in cylinder block (7).
6. Oil in quantity of (F)-(E) is drawn in and discharged from each
piston (6).
7. Pressurized oil is released while cylinder block (7) turns and the
volume of chamber (E) decreases.
8. Pressurized oil is drawn in as the volume of chamber (F)
increases.
9. When middle line (X) of the rocker (4) matches the axial of
cylinder block (7) (the swash plate angle is zero). The difference
between volumes (E) and (F) in the cylinder block (7) is zero.
10. Oil is not pressurized in this step.
11. The pump discharge volume is in proportion to swash plate angle
(a).
Control of released volume

1. When swash plate angle (a) increases, the difference between
volumes (E) and (F) increases, discharge volume (Q) also
increases.
2. The swash plate angle (a) adjusted by the servo piston (2).
3. Servo piston (2) moves in linear movement corresponding to the
signal pressure from the servo valve.
4. This linear movement is transmitted to rocker (4).
5. Rocker (4) held on to ball (11) and slides around the ball keeper
(11).
HD465-8, HD605-8 10-53

SERVO VALVE OF COOLING FAN PUMP

STRUCTURE OF SERVO VALVE OF COOLING FAN PUMP
P: EPC valve pressure port PH: Pump released pressure port

PE: Control piston pressure port T: Drain port
1: Lever 5: Piston
2: Retainer 6: Sleeve
3: Seat 7: Spring
4: Spool 8: EPC valve
10-54 HD465-8, HD605-8

FUNCTION OF SERVO VALVE OF COOLING FAN PUMP

The servo valve controls the relation between input current (i) to the
EPC valve and pump discharge volume (Q) as shown in the figure at
right.
OPERATION OF SERVO VALVE OF COOLING FAN PUMP
1. Output pressure of EPC valve goes into piston (C) and pushes piston (6).
2. Piston (6) pushes spool (5), and moves it to a position where it is balanced with spring.
3. Servo piston hole (PE) is connected to pump released pressure hole (PH) through notch in spool (5). The pump discharge
pressure is transmitted to servo piston (10).
4. When rocker (9) is pushed up by servo piston (10), lever (2) moves in the direction to compress spring (8).
5. When spool (5) is pushed back, the pump discharge circuit and servo piston circuit are disconnected.
HD465-8, HD605-8 10-55

6. Pressure in the servo piston chamber decreases, and rocker cam (9) goes back in the direction of maximum swash plate
angle.
7. This procedure is done again, and the swash plate is set to a position where EPC output pressure is balanced by the force
of spring (8).
8. When EPC pressure increases, swash plate angle decreases. When EPC output pressure decreases, swash plate angle
increases.
10-56 HD465-8, HD605-8

COOLING FAN MOTOR

STRUCTURE OF COOLING FAN MOTOR
General view
P: From cooling fan pump TC: To hydraulic tank

T: To hydraulic tank
HD465-8, HD605-8 10-57

Section view
1: Output shaft 8: Center spring

2: Case 9: Check valve
3: Thrust plate 10: Pilot valve
4: Piston 11: Reversible valve spool
5: Cylinder block 12: Safety valve
6: Valve plate 13: Speed sensor
7: End cover
Structure
The installed fan motor is in the vane width as shown in the figure.
10-58 HD465-8, HD605-8

SPECIFICATIONS OF COOLING FAN MOTOR

Model: LMF110 (90)
Type: Swash plate axial piston motor
Motor capacity: 90.3 cc/rev
Rated speed: 1300 rpm
Rated flow rate: 117.4 l/min
Check valve cracking pressure: 78.5 kPa {0.8 kg/cm2}
FUNCTION OF COOLING FAN MOTOR
This motor is a swash plate axial piston motor. It converts pressurized oil sent from the pump into rotary movement.
OPERATION OF COOLING FAN MOTOR
1. Pressurized oil flows from the pump through valve plate (6) to
cylinder block (5).
2. Pressurized oil flows to either side of (Y-Y) which connects to the
top middle and bottom middle during piston travel.
3. Pressurized oil which flows in either side of cylinder block (5)
pushes pistons (4) (4 pieces or 5 pieces).
4. Each piston generates force F1 (F1 kg = P kg/cm2 x πD2/4 cm2).

5. This force acts on the thrust plate (2).
6. Since the thrust plate (2) is set at angle (a) to the output shaft (1),
the force is divided into components (F2) and (F3).
7. Radial component (F3) of these components generates torque (T

= F3 x ri) against (Y-Y) which connects the top and bottom dead
centers.
8. Mixed force (T = Σ (F3 x ri)) of these torques turns cylinder block
(5) through pistons (4).
9. This cylinder block (5) is connected with output shaft (1) by
spline.
10. Output shaft (1) turns and transmits the torque.
HD465-8, HD605-8 10-59

SUCTION VALVE OF COOLING FAN MOTOR

FUNCTION OF SUCTION VALVE OF COOLING FAN MOTOR
q If the pump stops, the pressurized oil no longer flows into the mo-
tor.
q Since the motor continues to rotate with force, the pressure on
the out let side of the motor increases.
q When the oil flow stops from the inlet port (P), suction valve (1)
pulls in the oil on the out let side and supplies it to port (MA) which
compensates for the lack of oil on that side and prevents cavita-
tion.
OPERATION OF SUCTION VALVE OF COOLING FAN MOTOR

1. Pressurized oil is supplied from the pump to port (P), and the
pressure on (MA) side increases.
2. When initial torque is generated, the motor starts to rotate.
3. The pressurized oil on out let (MB) side of motor goes back to the
tank through port (T).
10-60 HD465-8, HD605-8

When the engine is stopped

1. When the engine is stopped, the input speed of the pump
becomes 0 rpm.
2. No pressurized oil is supplied from the pump to port (P).
3. No pressurized oil flows to (MA) side of the motor, and motor
speed decreases gradually to stop.
4. The motor shaft revolves by the inertial force while the pressur-
ized oil flow into the port (P) decreases. The suction valve
supplies pressurized oil in port (T) on the out let side to (MA) side
to prevent cavitation.
SAFETY VALVE OF COOLING FAN MOTOR

FUNCTION OF SAFETY VALVE OF COOLING FAN MOTOR
q The pressure in port (P) of the fan motor may increase at engine
startup.
q Safety valve (1) is installed to protect the fan system circuit.
HD465-8, HD605-8 10-61

OPERATION OF SAFETY VALVE OF COOLING FAN MOTOR

q When the pressure in port (P) exceeds the open pressure of
safety valve (1), valve (2) of safety valve (1) opens to release the
pressurized oil into port (T).
q This operation prevents abnormally high pressure in port (P).
REVERSIBLE VALVE OF COOLING FAN MOTOR

OPERATION OF REVERSIBLE VALVE OF COOLING FAN MOTOR
When the ON-OFF solenoid is de-energized
q When ON-OFF solenoid (1) is de-energized, the pressurized oil
from the pump stops by the ON-OFF selector valve (2). Then,
port (c) is connected to the tank circuit.
q Spool (3) is pushed to the right by spring (4).
q Motor port (MA) opens and the pressurized oil flows in, and the
motor positively turns (clockwise).
10-62 HD465-8, HD605-8

When the ON-OFF solenoid is energized

q When ON-OFF solenoid (1) is energized, ON-OFF selector valve
(2) is operated, pressurized oil from the pump flows into port (C),
and then into spool chamber (D).
q The pressurized oil goes into spool chamber (D), compresses
spring (4), and pushes spool (3) to left.
q Motor port (MB) opens and the pressurized oil flows in, and the
motor reversely turns (counterclockwise).
HD465-8, HD605-8 10-63

CONTROL SYSTEM DIAGRAM 10 STRUCTURE AND FUNCTION
CONTROL SYSTEM
CONTROL SYSTEM DIAGRAM
1: Engine controller B 9: Retarder and hoist controller

2: Engine controller A 10: Transmission controller
3: Rearview camera 11: KOMTRAX Plus controller
4: KOMTRAX terminal 12: KOMTRAX GPS antenna
5: Machine monitor 13: KOMTRAX communication antenna
6: Retarder control lever 14: Wireless LAN antenna
7: Rearview monitor 15: Wireless LAN unit
8: Monitor controller
10-64 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION RETARDER AND HOIST CONTROL SYSTEM
RETARDER AND HOIST CONTROL SYSTEM

RETARDER AND HOIST CONTROL SYSTEM DIAGRAM
HD465-8, HD605-8 10-65

RETARDER AND HOIST CONTROL SYSTEM 10 STRUCTURE AND FUNCTION
1: Monitor controller 24: KTCS hydraulic sensor (rear left) (optional)

2: Transmission controller 25: Steering oil temperature sensor
3: Engine controller 26: Retarder oil temperature sensor
4: KOMTRAX Plus controller 27: Secondary brake hydraulic sensor
5: Hoist lever kick-out solenoid 28: Accumulator oil pressure sensor (rear)
6: Secondary steering motor 29: Accumulator oil pressure sensor (front)
7: Brake lamp 30: Steering rudder angle speed sensor (optional)
8: Steering selection solenoid valve 31: Suspension hydraulic sensor (rear left)
9: Hoist selection valve 32: Suspension hydraulic sensor (rear right)
10: Hoist EPC valve 33: Secondary S/T oil pressure sensor
11: Retarder proportion pressure reducing valve 34: Steering oil pressure sensor
12: Automatic suspension solenoid 1 (optional) 35: Parking brake oil pressure sensor
13: Automatic suspension solenoid 2 (optional) 36: Rudder angle sensor
14: Front brake cut valve 37: Wheel speed sensor (rear left) (optional)
15: KTCS shutoff valve (optional) 38: Wheel speed sensor (rear right) (optional)
16: KTCS proportion pressure reducing valve (rear right) 39: ARSC vehicle speed setting switch
(optional) 40: Retarder oil pressure sensor
17: KTCS proportion pressure reducing valve (rear left) 41: Service brake operation switch
(optional) 42: Retarder lever potentiometer
18: Parking brake inter-lock relay 43: Dump body position sensor
19: Acceleration sensor 44: Electrical detent
20: Retarder and hoist controller 45: Hoist lever potentiometer
21: Front brake cut switch 46: Alternator terminal R
22: Inclination angle sensor 47: Start switch ACC terminal
23: KTCS hydraulic sensor (rear right) (optional)
10-66 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
MACHINE MONITOR SYSTEM

MACHINE MONITOR SYSTEM DIAGRAM
HD465-8, HD605-8 10-67

MACHINE MONITOR SYSTEM 10 STRUCTURE AND FUNCTION
1: Machine monitor 23: Service connector

2: LED unit 24: Coolant level sensor
3: LC unit 25: Air cleaner restriction sensor
4: Meter unit 26: Engine oil level sensor
5: Rearview camera 27: Monitor controller
6: Rearview monitor 28: System operation lamp
7: Switch panel 29: Night light for switch
8: Start switch 30: Night light for gear shift lever
9: Battery 31: Operation light for park switch
10: Alternator 32: Head lamp relay (high beam)
11: Fuel level sensor 33: Personal code relay
12: Dimmer switch 34: Alarm buzzer
13: Lamp switch 35: KOMTRAX Plus controller
14: Turn signal lever 36: Air conditioning controller
15: Seat belt switch 37: KOMTRAX terminal
16: Monitor intensity selection switch 38: Engine controller
17: Engine secondary shutdown switch 39: Retarder and hoist controller
18: Door switch 40: Transmission controller
19: Hazard lamp switch 41: CAN1
20: Automatic pre-heat relay 42: CAN2
21: High beam condition 43: LVDS
22: Unit switch connector 44: LIN
FUNCTION OF MACHINE MONITOR SYSTEM

The machine monitor system mainly includes the machine monitor, monitor controller, and switch panel.
Machine monitor
Shows the machine condition to the operator.
Monitor controller
Obtains and processes the condition data of different sections of the machine monitored with sensors and switches. Commu-
nicates the network information with each controller.
Switch panel
Accepts operations of the operator.
10-68 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION REARVIEW MONITOR SYSTEM
REARVIEW MONITOR SYSTEM

REARVIEW MONITOR SYSTEM DIAGRAM
Rearview monitor mainly includes the rearview monitor, rearview camera, and monitor controller.
FUNCTION OF REARVIEW MONITOR SYSTEM
This system shows the rearview image to the operator. This is based on the setting of the rear monitor controller (refer lines,
display of reverse-interlock, and luminance).
REMARK
In these conditions, it is necessary to readjust the lines to which the monitor refers.
q When the machine dimensions are changed because of replacement of tires or installation of optional equipment.
q When the rearview camera is removed or its direction is changed because of damage.
HD465-8, HD605-8 10-69

KOMTRAX PLUS SYSTEM 10 STRUCTURE AND FUNCTION
KOMTRAX PLUS SYSTEM

KOMTRAX PLUS SYSTEM DIAGRAM
1: Engine controller 5: CAN1 (KOMNET/r)

2: Transmission controller 6: CAN2 (KOMNET/c)
3: Retarder and hoist controller 7: KOMTRAX communication device
4: Monitor controller 8: KOMTRAX terminal
10-70 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION KOMTRAX PLUS SYSTEM
9: KOMTRAX communication antenna 27: PLM external lamp (green) (right)

10: Service connector 28: PLM external lamp (green) (left)
11: KOMTRAX GPS antenna 29: PLM external lamp (yellow) (right)
12: Start switch ACC signal 30: PLM external lamp (yellow) (left)
13: System operation lamp 31: PLM external lamp (red) (right)
14: Download switch outer side of cab 32: PLM external lamp (red) (left)
15: Download indicator outer side of cab 33: Inclination angle sensor
16: CAN3 (External supply) 34: Suspension pressure sensor (right front)
17: External supply connector 35: Suspension pressure sensor (left front)
18: Terminating resistor 36: Suspension pressure sensor (right rear)
19: Exhaust temperature sensor 37: Suspension pressure sensor (left rear)
20: Atmospheric temperature sensor 38: Service connector inner side cab
21: KOMTRAX Plus controller 39: LAN cable
22: Payload meter system 40: Service connector outer side cab *1
23: PLM protocol switch connector 41: Wireless LAN unit
24: RS232C 42: Wireless LAN antenna
25: PLM download connector in cab 43: LAN cable (PoE)
26: PLM download connector outer side of cab 44: Wireless LAN communication device
*1: Machine without wireless LAN communication device
HD465-8, HD605-8 10-71

FUNCTION OF KOMTRAX PLUS SYSTEM

1. Record and transmit function of vehicle information
q Record information obtained from each sensor and controller on the vehicle and transmit by wireless communication
using KOMTRAX terminal and wireless LAN unit.
q KOMTRAX Plus administrator sees the information in the office and supplies different services to the owner.
q KOMTRAX Plus controller transmits this information.
q Vehicle location information
q Operation information (service meter, speedometer)
q Alarm and troubleshoot information
q Fuel consumption information
q Maintenance information
q Information of how the machine is used
q Record of how the machine is used (operation record, error occurrence record)
q Obtaining information of the machine conditions and effect by age (trend data)
q Obtaining of information of the machine condition effect by time accumulation (map data)
q Failure analysis by real-time data (snapshot)
q Obtaining of information of how the machine is used by recorded operation (referred log data)
q Payload meter information
q Road surface information (optional)
REMARK
q The default setting of radio for KOMTRAX Plus is required to be set separately to use the service.
q Wireless communication is not available in a country with no permission to use it.
q To use KOMTRAX terminal or the wireless LAN unit or to change the country where you use them, make sure use is
approved by each country where the machine used.
q To use the machine in a country where the wireless LAN is not authorized. Install a download cable in the connector
out side of the cab. This lets you download the date by wire.
2. Payload meter function
q To calculate the load capacity from the information such as each suspension pressure, inclination angle, and to show
the load capacity on the machine monitor or external display lamp.
q To record the calculated load capacity and the related operation data of the individual cycle.
q For details, see "PAYLOAD METER SYSTEM".
3. Road surface analysis function (optional)
q To analyze or record the surface condition during operation from information such as suspension pressures, inclination
angle, steering angle, speed, and load capacity.
4. External supply function
q KOMTRAX Plus controller can transmit real-time data and failure codes obtained from each sensor and controller of
the machine to external devices by using J1939 communication.
q J1939 communication is defined by SAE J1939 and related standards.
q To use this function, connect the external device to the external supply connector inside the cab.
10-72 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION KOMTRAX PLUS SYSTEM
External supply connector position
1: External supply connector 2: KOMTRAX Plus controller
Connector information and input/output signal of the external supply connector (machine side)
Part number: DT04-12PC-BE02 (Receptacle)
Provided by: Deutsch
Color: Green
Required wedge P/N: W12P
Number of contacts: 12
Polarizing position: C
DT2C-12P "AUX"
No. Item Input/output signal

1 Continuous power supply (24 V) Output
2 Start switch ACC signal Output
3 CAN_H Input/output
4 (*1) -
5 (*1) -
6 Battery relay power supply (24 V) Output
7 KOMTRAX Plus output power supply (24 V) Output
8 (*1) -
9 (*1) -
10 CAN_L Input/output
11 (*1) -
12 GND (continuous power supply) -
*1: Never connect these pins. Malfunctions or failures may occur.

To connect external devices, connectors corresponding to the above items should be prepared by external devices side.
HD465-8, HD605-8 10-73

Terminating resistor and communication cable

q Two terminating resistors (120 Ω) are required for communication.
q One edge is attached to the machine side (8) and the other edge should be attached to the external device side (7).
q Twisted pair cables should be used for communication cable and the maximum lengths are shown in the table below.
A: The length from KOMTRAX Plus controller to the connec- B: The length from the terminating resistor to the connector
tor (0.5 m) (0.8 m)
1: External device side 5: External device
2: Machine side 6: KOMTRAX Plus controller
3: Twisted pair cable 7: Terminating resistor of external device side (120 Ω)
4: External supply connector 8: Terminating resistor of machine side (120 Ω)
Symbol Parameter Min (m) Max (m) Conditions

L Bus Length 0 40 not including cable stubs
S Cable Stub Length 0 1
d Node Distance 0.1 40
Resistance shall not be within an 3rd party
d0 Min. Distance from Resistance 0 -
component
10-74 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION PAYLOAD METER SYSTEM
PAYLOAD METER SYSTEM

PAYLOAD METER SYSTEM DIAGRAM
1: External display lamp (right) 6: Suspension pressure sensor (left rear)

2: Suspension pressure sensor (right front) 7: External display lamp (left)
3: Inclination angle sensor 8: KOMTRAX Plus controller
4: PLM download connector in cab 9: Suspension pressure sensor (left front)
5: Suspension pressure sensor (right rear) 10: PLM download connector outer side of cab
HD465-8, HD605-8 10-75

PAYLOAD METER SYSTEM 10 STRUCTURE AND FUNCTION
PAYLOAD METER SYSTEM DIAGRAM
1: Monitor controller 10: PLM external lamp (yellow) (right)

2: Transmission controller 11: PLM external lamp (red) (right)
3: Engine controller 12: PLM download connector
4: Retarder and hoist controller 13: KOMTRAX Plus controller
5: KOMTRAX terminal 14: Inclination angle sensor
6: PLM external lamp (green) (left) 15: Suspension pressure sensor (right rear)
7: PLM external lamp (yellow) (left) 16: Suspension pressure sensor (left rear)
8: PLM external lamp (red) (left) 17: Suspension pressure sensor (right front)
9: PLM external lamp (green) (right) 18: Suspension pressure sensor (left front)
FUNCTION OF PAYLOAD METER SYSTEM
q To show the load mass calculated from the information from each suspension pressure and to show the load by the external
display lamps.
q To measure the load mass if more load is loaded, and flash the corresponding external display lamp to prevent an over load.
q To record the loaded mass, travel distance, and tome of operation by the individual cycle. For the transported load mass,
the sample data sent during operate is recorded.
q The recorded cycle data downloads by use of the special software (optional).
10-76 HD465-8, HD605-8

REMARK
q The Payload meter system is one of the functions executed by KOMTRAX Plus controller.
When you replace KOMTRAX Plus controller, the setting of payload meter is required.
MEASUREMENT PRINCIPLE OF LOADING MASS
1. Overview
q The machines supported by each suspension cylinder, the pressure of the suspension cylinder provides the sum of the
load loaded on each suspension cylinder.
q Loads loaded on each cylinder calculate by the internal pressure and area of the suspension cylinder.
WS: Load on suspension cylinder SB: Area of cylinder

PB: Pressure on bottom side ST: Area of rod
PT: Pressure on head side
HD465-8, HD605-8 10-77

q Calculate the load (WS) on suspension cylinder as follows. [WS = PB x SB - PT (SB - ST)]
q The pressure on bottom side (PB) is equal to the pressure on head side (PT) because of the structure of suspension
cylinder. [PB ≈ PT]
q If it is assumed that [PB = PT] as described, the load applied to suspension cylinder (WS) then [WS = PB x ST].
q The loaded mass is decided by the difference between empty weight and loaded weight.
The empty weight and load weight calculated by the measurement data while you operate the machine with and without
load.
S: Slide resistance of suspension cylinder
F: Load provided from suspension pressure
W: Average load
T: Measurement time
q By measurement while in operation, the suspension cylinder is extended and contracted, the load (F) provided by the
suspension pressure during this period is averaged and recorded. Then the average load (W) which cancels the cylin-
der slide resistance (S) is provided.
q The calculated loaded mass is made sure of and recorded when dump soil.
2. Calibration
q An empty vehicle weight is calculated during travel. When the operation time is not enough or when the value of load
capacity is shown on the machine monitor. The empty weight measured before is used in weight calculation.
q The empty weight calculated by the measurement of the average load when the empty vehicle runs at about 10 km/h
for about 30 seconds on a flat ground.
The measured empty vehicle weight is recorded as a calibration data.
3. Calibration on a slope
If the dump truck is loaded on a slope, the measured mass is
different from the mass measured on a level ground. The solution
to this problem, the longitudinal inclination of the dump truck is
measured and the measured mass corrected by the inclination
angle. (When the increase slope is plus)
4. Measured travel distance and operation speed

q To calculate the travel distance by using the operation speed
information obtained from the monitor via communication.
DATA DOWNLOAD FUNCTION

q The recorded cycle data of payload meter downloaded by a computer with the installed software (optional) using the pay-
load meter download connector (RS232C communication port).
q For the contents and the download procedure of data, see "Operation and Maintenance Manual".
FUNCTIONS OF COMMUNICATING WITH EXTERNAL DEVICES FOR PURPOSES OTHER THAN DOWNLOADING
q These 2 functions of communication with external devices are installed. They use the RS232C communication port which
is installed to download the data of the payload meter.
1. Automatic transmission
When your dump is completed, the data of the applicable cycle is transmitted automatically.
The data kept in the payload meter is made by accumulation of the cycle data with the system.
10-78 HD465-8, HD605-8

2: MMS communication
If the mass of a bucket full is recognized, the load mass at that time is transmitted automatically.
If the last load mass (moved load mass of the applicable cycle) is recorded, its value is transmitted automatically.
Upon a request, the load mass is transmitted in real time.
q As there is only one payload meter download connector (RS232C communication port), the PLM supply connector se-
lects one function from the data download, automatic transmission, or MMS communication.
q Specifications of RS232C connection
Baud rate: 9,600 bps
Data length: 8 bits
Start bit: 1 bit
Stop bit: 1 bit
Parity: Not applied
q Connection of RS232C (communication line) (3-wire procedure)
1: KOMTRAX Plus (CN-KPS2) 3: Part to be prepared by user

2: CN-PLMm (in cab) 4: Connected external devices
CN-PDL (external cab))
q PLM protocol switch connector
1: CN-HM55 4: When automatic transmission is selected

2: Part to be prepared by user 5: When MMS communication is selected
3: When download is selected (Standard)
*1: A, B, and C are open
q Difference of communication control codes
The transmit side transmits data as explained below. The data in a communication frame starts with STX and finishes
with EXT and BCC and will be transmitted with permeability.
1) If there is a code which is the same as STX or ETX in the data area of the communication frame. DLE (10h) is put
just before that code.
HD465-8, HD605-8 10-79

2) If there is a code which is the same as DLE in the data area of the communication frame. DLE (10h) is put just
before that code.
3) Calculate of BCC
XOR (Exclusive-or) is examined in sequence from STX at the head of the frame to ETX just before BCC, which
includes the insert of DLE.
When one of 02h (STX), 03h (ETX), and 10h (DLE) is included in the data
q Initial frame
STX (02h) ··· STX (02h) ··· ETX (03h) BCC
q Transmitted frame
STX (02h) ··· DLE (10h) STX (02h) ··· ETX (03h) BCC
q Automatic transmission
(a) Time of transmission
The operation data of the applicable cycle is transmitted automatically when the applicable cycle data is recorded
(When the dump is finished).
(b) Contents of communication
Format (KOMTRAX Plus controller o External device)
STX (02h) [1] ETX (03h) BCC
[1]: Cycle data {39 bytes includes header (ASCII L)}

Number of
Item Unit Range Remarks
byte
Header "L" ASCII 1 L (Set)
New Integer 1 to 65535 2 0 (Set)
Month Month (BCD) 1
Day Day (BCD) 1
Time, hour Hour (BCD) 0 to 23 expression 1
Time, minute Minute (BCD) 1
Truck ID Integer 0 to 200 1
Open ID Integer 0 to 200 1
Load mass Metric ton (10-time value) 0 to 6553.5 2
Empty travel time MIN (10-time value) 0 to 6553.5 2
Empty travel distance km (10-time value) 0 to 25.5 1
Empty max. travel speed km/h 0 to 255 1
Empty average travel speed km/h 0 to 255 1
Empty stop time MIN (10-time value) 0 to 6553.5 2
Stop time for load MIN (10-time value) 0 to 6553.5 2
Loaded travel time MIN (10-time value) 0 to 6553.5 2
Loaded travel distance km (10-time value) 0 to 25.5 1
Loaded max. travel speed km/h 0 to 255 1
Empty average travel speed km/h 0 to 255 1
Loaded stop time MIN (10-time value) 0 to 6553.5 2
Dump time MIN (10-time value) 0 to 25.5 1
Limited speed km/h 0 to 99 1
Cycle warning code 0-FFFF (HEX) 2
New V (10-time value) 0 to 4.0 1 0 (Set)
New Time 0 to 255 1 0 (Set)
New Time 0 to 255 1 0 (Set)
[BCC]: EX-OR of each bit from STX to ETX
10-80 HD465-8, HD605-8

Answer (External device o KOMTRAX Plus controller)

STX (02h) NAK (15h) 31H (ASCII 1) ETX (03h) BCC
Steps that KOMTRAX Plus controller takes when answer is abnormal

If "NAK" is returned, the controller transmits 2 more times. If "NAK" continues, the controller transmit stops.
q MMS communication
1) Sending of the unit of weight distinction setting
The KOMTRAX Plus controller automatically sends the unit of weight distinction setting information after it is
activated with the key "ON".
Format (KOMTRAX Plus controller o)
STX (02h) [1] [2] ETX (03h) BCC
[1]: K (ASCII) set
[2]: 02 (h) set (Unit class [HEX])
Answer (o KOMTRAX Plus controller)
STX (02h) ACK (06h) 31H (ASCII 1) ETX (03h) BCC
or

If "NAK" is returned or either of "ACK" and "NAK" is not returned in 3 seconds, the controller transmits up to 2
more times. If no answer continues, the controller stops transmission.
2) Transmission of load mass, estimate load mass, and suspension pressure

When the mass of 1 full bucket is recognized
HD465-8, HD605-8 10-81


STX (02h) [1] [2] [3] [4] [5] [6] ETX (03h) BCC
[1]: M (ASCII) set

[2]: 4 (ASCII) set
[4]: Load mass (B) [HEX] (2 BYTES) (Unit: Metric ton, 10-time value, 1 decimal position)
[5]: Estimate load mass (C) [HEX] (2 BYTES) (Unit: Metric ton, 10-time value, 1 decimal position)
[6]: (B) Calculated suspension pressure [HEX] (8 BYTES)
From head
Signal
Position Name HEX
name
(Lower
position)
P FL
(Upper Front left suspension pressure (kg/cm2) [10-time value] 0 to 6553.5
position)
(Lower
position)
P FR
(Upper Front right suspension pressure (kg/cm2) [10-time value] 0 to 6553.5
position)
(Lower
position)
P RL
(Upper Rear left suspension pressure (kg/cm2) [10-time value] 0 to 6553.5
position)
(Lower
position)
P RR
(Upper Rear right suspension pressure (kg/cm2) [10-time value] 0 to 6553.5
position)
10-82 HD465-8, HD605-8


or

3) Transmission of last load mass

When the applicable cycle data is recorded (When dump is completed), the last load mass (= the load mass to
be kept as the moved load mass of the applicable cycle in the memory) is transmitted automatically.

Format (KOMTRAX Plus controller →)
STX (02h) [1] [2] ETX (03h) BCC
[1]: P (ASCII) set

[2]: Load mass [HEX] (2 BYTES) (Unit: Metric ton, 10-time value, 1 decimal position)
Sequence: Lower position o upper position from the head byte of [2]

or

4) Transmission of real-time data

(a) Outline of communication procedure
1]The KOMTRAX Plus controller receives a request for the real-time data from MMS.
2]After you receive the request for the real-time data, the KOMTRAX Plus controller transmits the real-time data
at intervals of 0.2 seconds.
3]When the KOMTRAX Plus controller receives a request to complete transmission of the real-time data, it
completes transmission of the real-time data.
When the key is turned to the OFF position, transmission of the real-time data is finished, too.

1]Request for real-time data
Format (→ KOMTRAX Plus controller)
STX (02h) [1] [2] ETX (03h) BCC
[1]: M (ASCII) set
[2]: 2 (ASCII) set
HD465-8, HD605-8 10-83

Answer (KOMTRAX Plus controller o)

Transmission of the real-time data from the KOMTRAX Plus controller is used as an alternative for the an-
swer.
2]Transmission of real-time data
STX (02h) [1] [2] [3] [4] ETX (03h) BCC
[1]: M (ASCII) set

[2]: 2 (ASCII) set
[4]: Real-time data (17 BYTES)
From head
Signal
Position Name HEX
name
(Lower
position)
P FL
(Upper Front left suspension pressure (kg/cm2) [10-time value] 0 to 6553.5
position)
(Lower
position)
P FR
(Upper Front right suspension pressure (kg/cm2) [10-time value] 0 to 6553.5
position)
(Lower
position)
P RL
(Upper Rear left suspension pressure (kg/cm2) [10-time value] 0 to 6553.5
position)
(Lower
position)
P RR
(Upper Rear right suspension pressure (kg/cm2) [10-time value] 0 to 6553.5
position)
(Lower
[Complement of 2 of 100-time
position)
INC Inclination angle (degree) value]
(Upper
-9.99 to +9.99
position)
(Lower
position) Real-time load mass [10-time value, to 1 decimal
PAYLD
(Upper (Metric ton) position]
position)
SP (Current) Travel speed (km/h) 0 to 99
DIG STST Status of digital signals See (*1)
ANA 1 New 0
ANA 2 New 0
VEH STAT Status of dump truck See (*2)
(*1) Status of digital signals [HEX]
bit0: Gear shift lever N signal 1. Gear shift lever N (OPEN) 0: Gear shift lever is not N (GND)
bit1: Hoist lever signal 1: FLOAT (OPEN) 0: Not FLOAT (GND)
bit2: Engine rotation/stop
1: Engine rotation (OPEN) 0: Engine stop (GND)
recognition
bit 3: New
bit 4: New
bit 5: New
bit 6: New
bit 7: New
10-84 HD465-8, HD605-8

(*2) Status of dump truck [HEX]

00 (h): Engine stopped
01 (h): Empty and stopped
02 (h): Empty and traveling
03 (h): Loading
04 (h): Loaded and traveling
05 (h): Loaded and stopped
06 (h): Unloading
STX (02h) ACK (06h) ETX (03h) BCC
or
STX (02h) NAK (15h) ETX (03h) BCC

If "NAK" is returned or any of "ACK", "NAK", and a request to complete RTM is not returned in RTM time,
the controller transmits real-time data. Usually after 0.2 seconds. If this condition is done 10 times, the con-
troller stops transmission.
3]Request for complete transmission of real-time data (o KOMTRAX Plus controller)

Format
STX (02h) [1] [2] ETX (03h) BCC
[1]: Q (ASCII) set

[2]: 2 (ASCII) set
Answer (KOMTRAX Plus controller o)
STX (02h) ACK (06h) ETX (03h) BCC
or
STX (02h) NAK (15h) ETX (03h) BCC
HD465-8, HD605-8 10-85

MACHINE LOCK-OUT SYSTEM 10 STRUCTURE AND FUNCTION
MACHINE LOCK-OUT SYSTEM

LAYOUT DRAWING OF MACHINE LOCK-OUT SYSTEM
(For machine with machine lock-out system)
1: Machine lock-out operation lamp

2: Machine lock-out operation switch
3, 4: Machine lock-out selector valve
5: Steering and hoist filter
10-86 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION MACHINE LOCK-OUT SYSTEM
FUNCTION OF MACHINE LOCK-OUT SYSTEM

The machine lock-out system prevents specific devices from working while the engine is running. While the machine lock-out
system is activated, the following devices do not work even if they are operated.
q Gear shift lever
q Dump lever
q Steering wheel
q Parking brake switch
NOTICE
Even when the machine lock-out is activated, the machine works if the following operations are performed.
q Operations of secondary steering switch
q Manual release of parking brake
q Lower the dump body manually
OPERATION OF MACHINE LOCK-OUT SYSTEM
1. Raise the cover (1).
2. When the machine lock-out operation switch is turned to the

upper position (A), the machine lock-out is activated.
When the switch is turned to the lower position (B), the machine
lock-out is deactivated.
HD465-8, HD605-8 10-87

CONTROL SYSTEM COMPONENTS 10 STRUCTURE AND FUNCTION
CONTROL SYSTEM COMPONENTS

MACHINE MONITOR
FUNCTION OF MACHINE MONITOR
q The machine monitor has the monitor display function and mode selection function. It also has the warning buzzer.
q CPU (Central Processing Unit) is installed, and it processes, displays, and outputs information.
REMARK
q If there is abnormality in the machine monitor, controller, or wires between the machine monitor and controller, the machine
monitor does not show correctly.
q The battery voltage may fall quickly when the engine is started dependent on the ambient temperature and battery condi-
tion. In this case, the display may disappear for a while, but it is not abnormal.
q For details of these, see "Operation and Maintenance Manual".
q Display (Shown on screen)
q Switch part
q Guidance icons
10-88 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION CONTROL SYSTEM COMPONENTS
INPUT AND OUTPUT SIGNALS OF MACHINE MONITOR

JAE-8P "DPC1" (for LC unit)
Pin No. Signal name Input/output signal

1 LC unit LVDS + Input
2 LC unit LVDS - Input
3 GND (LC unit power supply) -
4 LC unit backlight adjustment Input
5 LC unit power supply Input
6 LC unit ON/OFF control Input
7 LC unit backlight ON/OFF control Input
8 LC unit temperature sensor Input
AMP-6P "DPC2" (for LED unit)

1 LED unit power supply (+12 V) Input
2 GND (LED unit power supply) -
3 LIN Input/output
4 LED unit power supply (+5 V) Input
5 (*1) -
6 (*1) -
AMP-8P "DPC3" (for meter unit)

1 Continuous power supply (24 V) Input
2 Start switch ACC signal Input
3 CAN2_H Input/output
5 Monitor intensity selection switch (night mode signal) Input
6 (*1) -
7 CAN2 terminating resistor Input
8 CAN2_L Input/output
HD465-8, HD605-8 10-89

TYPES OF GAUGES AND METERS SHOWN ON MACHINE MONITOR

Gauge Item shown Description Remarks
q If communication error occurs be-
tween monitor controller and trans-
mission controller, 0 is shown.
Speedometer 0 to 99 km/h
q When communication error occurs
between monitor controller and me-
ter unit, 00 is shown.
q When engine speed increases
above specified level, engine over-
run caution lamp illuminates.
0 to 3500 rpm
Engine tachometer (For details, see engine overrun cau-
(Red zone: 2500 rpm and above)
tion lamp)
q If communication error occurs,
gauge reads 0.
Coolant
Monitor
Range temperature
background
(°C)
q When temperature exceeds 102 °C,
A1 135 Red engine coolant temperature caution
lamp illuminates.
Engine coolant A2 102 Red
(For details, see engine coolant tem-
temperature gauge
A3 88 Green perature caution lamp)
q When communication error occurs,
A4 74 Green the gauge pointer disappears.
A5 59 Green
A6 50 White
Oil
Monitor
Range temperature
background
(°C)
B1 135 Red torque converter oil temperature
Torque converter oil
B2 120 Red caution lamp illuminates.
temperature gauge
B3 97 Green the gauge pointer disappears.
B4 73 Green
B5 50 Green
Oil
Monitor
Range temperature
background
(°C)
C1 150 Red retarder oil temperature caution lamp
Retarder oil temperature
C2 120 Red illuminates.
gauge
C3 97 Green the gauge pointer disappears.
C4 73 Green
C5 50 Green
Fuel level Monitor
Range
(l) background
D1 725 Green q When fuel level is 126 ℓ or below, fuel
D2 585 Green level caution lamp illuminates.
Fuel gauge
q When sensor error occurs, the
D3 390 Green gauge pointer disappears.
D4 126 Red
D5 90 Red
10-90 HD465-8, HD605-8

Gauge Item shown Description Remarks

q Indicates fuel consumption (average
of fuel consumption by 3 seconds) in
10 steps.
(Select the User Menu Energy Sav-
ing Guidance→Configurations→
ECO Gauge Display, to select set-
0 to 148 ℓ/h (orange zone: 119 ℓ/h
ECO gauge ting for display or no display.)
and above)
(Select the User Menu Energy Sav-
ing Guidance→Configurations→
ECO Gauge Display to set Fuel Tar-
get Value, and display range.)
gauge reads 0.
q Set temperature
For details, see Operation and
Air conditioner display q Airflow rate
Maintenance Manual.
q Vent
Shows the time.

q 12-hour system display (AM/PM) (Select the User Menu Monitor Setting
Clock
q 24-hour system display →Clock Adjustment, to set 12 hours or
24 hours display.)
q Indicates accumulated engine oper-

ation hours.
Service meter (*1) 0 to 999999.9 h q When operation hour exceeds
999999.9 h, meter indication stops at
999999.9 h.
q Indicates accumulated travel dis-
tance.
Odometer (*1) 0 to 3999999.9 km q When travel distance exceeds
3999999.9 km, meter indication
stops at 3999999.9 km.
q Shows the time.
(Select the User Menu Monitor Set-
ting→Clock Adjustment, to set 12
hours or 24 hours display.)
q 12-hour system display (AM/PM) q On machine with payload meter
Clock (*1)
q 24-hour system display specification, time is displayed when
payload is below specified load (15
% of max. payload by default).
When payload exceeds specified
load, payload meter is shown.
Indicates average fuel consumption.
(Select the User Menu Energy Saving
Fuel consumption gauge q 1-day system display
Guidance→Configurations→Average
(*1) q Split display
Fuel Consumption Display, and setting
for display selected.)
q Displays payload.
q When payload exceeds specified
level (15 % of rated payload by de-
fault), clock display section changes
to payload meter display.
Payload meter 0 to 99999.9 t q When payload exceeds 99999.9 t,
meter indication stops at 99999.9 t.
q For details, see TEST AND AD-
JUST, "PAYLOAD METER SET-
TING" or Operation and
Maintenance Manual.
HD465-8, HD605-8 10-91

*1: Select the User Menu Monitor Setting→Meter Display Selection, to select the items that follow to show on L.H. meter and
R.H. meter.
L.H. meter: Service meter, speedometer, clock
R.H. meter: Service meter, speedometer, clock, fuel consumption gauge
TYPES OF CAUTION LAMPS SHOWN ON MACHINE MONITOR
Description
Caution
Symbol Item shown lamp Action Remarks
Range display level
(background display
color)
When action level Illuminates q Centralized warning lamp illumi-
L04
L04 is sensed (red) nates when a defect is sensed in
machine.
When action level Illuminates Alarm buzzer operates continuously
L03 q
L03 is sensed (red) when the monitor back ground color
Action level is red and action level L04 is shown,
When action level Illuminates alarm buzzer operates intermittently
L02 when action level L02 or L03 is
L02 is sensed (red)
shown.
When action level Illuminates Caution lamp illuminates for 2 seconds,
L01
L01 is sensed (yellow) and then goes out.
When a failure of above the action level
When sensed action L02 occurs for operator's attention, the
Illuminates
Centralization level is L02 and - centralized warning lamp illuminates
(red)
above and alarm buzzer operates
intermittently at the same time.
Centralized warning lamp illuminates
When it is abnormal and alarm buzzer operates
while the engine intermittently when the brake oil
L03
operates (below the pressure decreases while engine
specified value) operates.

When it is abnormal Illuminates
Brake oil pressure and alarm buzzer operates
while the engine (red)
- intermittently when the brake oil
starts (below the
pressure does not increased after
specified value)
engine starts.
When it is abnormal
Caution lamp illuminates if the brake oil
when the engine
- pressure is low while the engine is
stops (below the
stopped.
specified value)
When coolant temperature is 105 °C or
more, centralized warning lamp
Min. 105 °C L02
illuminates and alarm buzzer operates
Illuminates intermittently.
(red)
When temperature exceeds 102 °C,
Engine coolant
Min. 102 °C - engine coolant temperature caution
temperature
lamp illuminates.
Illuminates
(white)
Below 102 °C -
Illuminates
(green)
10-92 HD465-8, HD605-8

Description
Caution
Range display level
(background display
color)
Illuminates When torque converter oil temperature
Min. 120 °C L02
Torque converter oil (red) is 120 °C or more, centralized warning
temperature Illuminates lamp illuminates and alarm buzzer
Below 120 °C - operates intermittently.
(green)
Illuminates When retarder oil temperature is 120
Min. 120 °C L02
Retarder oil (red) °C or more, centralized warning lamp
temperature Illuminates illuminates and alarm buzzer operates
Below 120 °C - intermittently.
(green)
Illuminates
Max. 126 ℓ
(red) Illuminates when fuel level is 126 ℓ or
Fuel level -
Illuminates below.
Above 127 ℓ
(green)
Maintenance due Illuminates q Illuminates for 30 seconds after
time is over (red) start switch is turned to the ON posi-
tion when past the maintenance
time of any item.
Maintenance due
- q Change maintenance notice time on
time When maintenance Illuminates the Service Menu Maintenance
notice time is over (yellow) Mode Setting → Maintenance Mode
Change → Maintenance Notice
Time Setting.
When seatbelt is not Illuminates

Seat belt -
connected (red)
When action level q Caution lamp illuminates when an

Illuminates L04 or
L04 or L03 is abnormality is found in engine sys-
(red) L03
sensed tem.
q Monitor background is red and cen-
Engine system (*2) tralized warning lamp illuminates,
When action level Illuminates alarm buzzer operates continuously
L01 when action level L04 is shown, and
L01 is sensed (yellow)
alarm buzzer operates intermittently
when action level L03 is shown.
When action level q Caution lamp illuminates when a
Illuminates L04 or
L04 or L03 is defect is sensed in the KDPF sys-
(red) L03
sensed tem.
KDPF system (*2) tralized warning lamp illuminates,
HD465-8, HD605-8 10-93

Description
Caution
Range display level
(background display
color)
When action level Illuminates q Caution lamp illuminates when too
L03
L03 is sensed (red) much soot is accumulated in KDPF
or a system failure such as reduced
KDPF soot filter function of KDPF is sensed.
accumulation (*2) When action level Illuminates q Monitor background color is red and
L01 centralized warning lamp illumi-
nates, and alarm buzzer operates
intermittently.
Engine speed Illuminates
L02 Centralized warning lamp illuminates,
Min. 2625 rpm (red)
Engine overrun (*2) and alarm buzzer operates
Engine speed Illuminates intermittently.
-
2400 rpm (red)
Caution lamp illuminates and alarm

When abnormal
Engine oil pressure Illuminates buzzer operates intermittently when an
(below specified L03
(*2) (red) abnormality is sensed while the engine
pressure)
operates.
When action level q Caution lamp illuminates when a

Illuminates L04 or
L04 or L03 is defect is sensed in the transmission
(red) L03
sensed system.
Transmission system
tralized warning lamp illuminates,
(*2)
When action level Illuminates q Caution lamp illuminates when a
L03
L03 is sensed (red) defect is sensed in the fan control
system.
Fan control system
q Monitor background color is red and
(*2) When action level Illuminates
L01 is sensed (yellow) nates, and alarm buzzer operates
intermittently.
When gear shift
lever is in a position
other than N or Monitor background color is red and
Wrong operation
dump body is in a Illuminates centralized warning lamp illuminates,
during fan reverse -
position other than (red) and alarm buzzer operates
mode (*2)
seated while intermittently.
radiator fan is
reversed.
When a charge
system defect is
sensed for longer
L03
than specified time Monitor background color is red and
while engine Illuminates centralized warning lamp illuminates,
Battery charge (*2) operates. (red) and alarm buzzer operates
When a charge intermittently.
system defect is
-
sensed while engine
operates.
10-94 HD465-8, HD605-8

Description
Caution
Range display level
(background display
color)
After the engine ran 1 hour or more
with the radiator coolant level below the
specified level, when the starting switch
When abnormal is Illuminates is turned to the ON position again, the
L02
left. (red) caution lamp lights up. At the same
Radiator coolant level time, the centralized warning lamp
(*2) lights up and the alarm buzzer operates
intermittently.
When abnormal
Illuminates Caution lamp illuminates if a defect is
(below specified L01
(yellow) sensed while engine operates.
level)
When abnormal
Illuminates Caution lamp illuminates if a defect is
Engine oil level (*2) (below specified L01
(yellow) sensed when engine stops.
pressure)
When abnormal
Air cleaner restriction Illuminates Caution lamp illuminates if a defect is
(above specified L01
(*2) (yellow) sensed while engine operates.
pressure)
When abnormal
Transmission oil filter Illuminates Caution lamp illuminates if a defect is
(above specified L01
clogging (*2) (yellow) sensed while engine operates.
pressure)

L03
L03 is sensed (red) defect is sensed in the retarder sys-
tem.
Retarder system (*2) q Monitor background color is red and
When action level Illuminates centralized warning lamp illumi-
L01
intermittently.
L03
L03 is sensed (red) defect is sensed in the parking
brake system.
Parking brake system
(*2) When action level Illuminates
intermittently.
KTCS system (*2) When action level Illuminates Caution lamp illuminates when a defect
L01
(KTCS specification) L01 is sensed (yellow) is sensed in the KTCS system.
When action level Illuminates Caution lamp illuminates when a defect

Steering system (*2) L01
L01 is sensed (yellow) is sensed in the steering system.
HD465-8, HD605-8 10-95

Description
Caution
Range display level
(background display
color)
L03
L03 is sensed (red) defect is sensed in the secondary
steering system.
Secondary steering
system (*2) When action level Illuminates
intermittently.
L03
L03 is sensed (red) defect is sensed in the hoist control
system.
Hoist controller
intermittently.
When it is abnormal
and alarm buzzer operates
while the engine
L03 intermittently when the steering oil
operates (below the
pressure decreases while engine
specified value) Illuminates operates.
(red)
When it is abnormal
Steering oil pressure Alarm buzzer operates intermittently
while the engine
(*2) - when the steering oil pressure is not
starts (below the
increased after engine starts.
specified value)
When it is abnormal
It illuminates when the steering oil
when the engine Illuminates
- pressure is low while the engine is
stops (below the (yellow)
stopped.
specified value)
When steering oil temperature is 100
°C or more, the monitor background
Steering oil Illuminates
Min. 100 °C L02 color is red and the centralized warning
temperature (*2) (red)
lamp illuminates, and the alarm buzzer
operates intermittently.
When the secondary steering motor is
used for 60 second, the monitor
Secondary steering
Secondary steering Illuminates background color is red and the
motor is used for 60 L02
motor (*2) (red) centralized warning lamp illuminates,
seconds or more.
and the alarm buzzer operates
intermittently.
When the hoist When the hoist lever is in RAISE
lever is in the position and lateral inclination angle is
raise position and Illuminates too much, the monitor background
Inclination (*2) -
the lateral (red) color is red and the centralized warning
inclination angle lamp illuminates, and the alarm buzzer
is too much. operates intermittently.
10-96 HD465-8, HD605-8

Description
Caution
Range display level
(background display
color)
When the hoist lever is not in FLOAT or
When hoist lever
when gear shift lever is not in N while
is not in FLOAT
dump body is raised, the monitor
or when gear shift Illuminates
- background color is red and the
lever is not in N (red)
centralized warning lamp illuminates,
while dump body
and the alarm buzzer operates
Body float (*2) is raised.
intermittently.
Hoist lever is not
in FLOAT or
Illuminates It illuminates when the hoist lever is not
when dump body -
(yellow) in FLOAT or when dump body is raised.
is raised
condition.
When action level Illuminates q It illuminates when a defect in the
L03
L03 is sensed (red) machine monitor or rearview moni-
tor, and communication error be-
tween controllers are sensed.
System (*2)
When action level Illuminates q Monitor background color is red and
intermittently.
Air conditioner When action level Illuminates Caution lamp illuminates when a defect
L01
system (*2) L01 is sensed (yellow) is sensed in the air conditioner system.
Payload meter When action level Illuminates Caution lamp illuminates when a defect
L01
system (*2) L01 is sensed (yellow) is sensed in the payload meter system.
Action level Illuminates Caution lamp illuminates when a defect

ARSC system (*2) L03
L03 is sensed (red) is sensed in the ARSC system.
Fast rise of retarder

It illuminates when oil temperature
ARSC overheat oil temperature Illuminates
- quickly rises while ARSC is in
Notice (*2) while ARSC is in (yellow)
operation.
operation
q Caution lamp illuminates during ac-

celerating at a slope, etc. until the
Overspeed (*2)
retarder brake starts to operate
(Maximum speed limit Accelerates on a
Illuminates while the speed limit is used.
and speed limit during slope, while the -
(red) q Monitor background color is red and
overload speed limit is used.
centralized warning lamp illumi-
specification)
intermittently.
HD465-8, HD605-8 10-97

Description
Caution
Range display level
(background display
color)
q Caution lamp illuminates when pay-
load exceeds specified level (pay-
Overload (*2) load meter external display lamp
When payload
(Speed limit during Illuminates illuminates +5%).
exceeds specified -
overload (red) q Monitor background color is red and
level
specification) centralized warning lamp illumi-
intermittently.
Automatic
suspension control
Caution lamp illuminates when a defect
L01 is sensed in the control system of the
(Automatic L01 is sensed (yellow)
automatic suspension.
suspension
specification)
While the parking
Wrong operation of brake is set to Monitor background color is red and
machine lock-out "Release", the Illuminates centralized warning lamp illuminates,
-
(Machine lock-out machine lock-out (red) and alarm buzzer operates
specification) switch is turned to intermittently.
ON position.
*2: When 3 or more caution lamps are generated at the same time, the icons are shown two by two in 2 seconds intervals.
10-98 HD465-8, HD605-8

TYPES OF PILOT LAMPS DISPLAYED ON MACHINE MONITOR

Symbol Item shown Description Remarks
q Illuminates: Lock
Parking brake Indicates condition of parking brake.
q Lights off: Free
Flash: When you turn to the left

Turn signal lamp (left)
direction
Illuminates: When upper head lamp

Head lamp (high beam)
comes on
Flash: When you turn to the right

Turn signal lamp (right)
direction
Illuminates: When clearance lamp

Clearance lamp
comes on
q E and gear speed are shown one

after the other in an emergency
machine failure.
q When the torque converter stalls
Display: gear speed (F1, F2, F3, F4, with gear shift in D, F1 Start at D
Shift indicator
F5, F6, F7, R) Position set, character F1 flashes
on the shift gauge. The central-
ized warning lamp illuminates,
and the alarm buzzer sounds. (F1
stall alarm)
q When start switch is turned to ON
position while gear shift lever is
not in N, character of gear shift le-
ver position flashes, centralized
warning lamp illuminates and
alarm buzzer operates. (Neutral
Highlighting: Gear shift lever position
Gear shift lever position safety alarm)
(L, 2, 3, 4, 5, 6, D, N, R)
q When all signals from gear shift
lever are OFF, character of cur-
rent gear shift lever position
flashes, centralized warning lamp
illuminates and alarm buzzer
sounds.
q Illuminates: There is an unread

Message (unread) message. Shows the condition of message.
q Lights off: No message
q Illuminates: There is a read and no

Message (read, no reply) reply message. Shows the condition of message.
q Lights off: No message
HD465-8, HD605-8 10-99

Illuminates: When retarder is in

Retarder
operation
q Illuminates: When KTCS is in oper-

When KTCS operates
ation
(KTCS specification)
q Lights off: When KTCS is stopped
q Illuminates: When KTCS setting is

KTCS Setting OFF
(KTCS specification) q Lights off: When KTCS setting is
ON
q Illuminates: Aftertreatment Devic-

Aftertreatment Devices es Regeneration is in progress. Indicates regeneration condition of
Regeneration q Lights off: Aftertreatment Devices after treatment devices.
Regeneration completed
q Indicates regeneration condition

q Illuminates: Aftertreatment Devic-
of after treatment devices.
es Regeneration disabled
Aftertreatment Devices q When manual stationary regener-
q Lights off: When Aftertreatment
Regeneration disabled ation is necessary, KDPF soot
Devices Regeneration disabled is
accumulation caution lamp illumi-
canceled.
nates.
Illuminates: When secondary steering

Secondary steering
is activated
Torque converter lockup Illuminates: When lockup is activated
q Illuminates: Radiator fan turns in

reverse.
Fan rotation opposite
q Lights off: Radiator fan turns cor-
rectly.
When engine coolant temperature is

Illuminates: When engine pre-heat is
Pre-heating low, the engine pre-heat operates
in operation
automatically up to 45 seconds.
q Excessive engine idle guide lines

q Procedure of hoist pressure relief
event
q Guide lines of brake drag event
q Procedure for recommended Displays that the fuel consumption is
ECO guidance
Trans upshift increased during machine operation.
q Procedure to accelerate while the
dump body is lowered
q Guide lines of S/T pressure relief
event
Illuminates: When the front brake cut

Front brake cut
switch is set to ON
10-100 HD465-8, HD605-8

Illuminates (green): ARSC operation is

available or in operation
ARSC operation
Illuminates (white): ARSC is not in
operation
Illuminates: When ARSC setting is

ARSC setting OFF
Lights off: When ARSC setting is ON
Illuminates: When the maximum

Maximum speed limit
speed limit is in operation
(Maximum speed limit
Lights off: When the maximum speed
specification)
limit is stopped
Suspension mode (hard)

Illuminates: When the automatic
(Automatic suspension
suspension is in hard mode
specification)
Suspension mode (medium)

suspension is in medium mode
specification)
Suspension mode (soft)

suspension is in soft mode
specification)
Illuminates: When the machine

Machine lock-out
lock-out is in operation
(Machine lock-out
Lights off: When the machine lock-out
specification)
is not in operation.
HD465-8, HD605-8 10-101

OPERATOR MODE FUNCTION OF MACHINE MONITOR

q The information items in this mode are shown ordinarily. The operator can display and set them by operating the switches.
Display and setting of some items have special operations of the switches.
q Items available in the operator mode are as follows:
Category Display sequence (*2)

Item
(*1) W X Y Z
Display of KOMATSU logo 1 1 1 1
Display of password input 2 - 2 -
Display of check before you start 3 2 3 2
Display of warning after check before you start - - 4 -
A
Display of past due maintenance - - - 3
Display of standard screen 4 3 5 4
Display of engine secondary shutdown switch screen
Display of end screen
Operation of air conditioner
Setting and display of user menu
q Energy Saving Guidance
B q Machine Setting and Information
q Aftertreatment Devices Regeneration
q Maintenance
q Monitor Setting
q User Message (included in KOMTRAX messages for owner)
ECO Guide line Display
Display of caution lamp
C
Display of past due maintenance
Display of Aftertreatment Devices Regeneration
Examine function of LCD (Liquid Crystal Display)
D Examine function of service meter and speedometer
Function of usage limitation setting/change password
*1: The operator mode items are classified as follows.

A: Display from the time when the start switch is turned to ON position to the time when display changes to the standard screen.
Display after start switch is turned to OFF position
B: Display when the machine monitor switch is operated
C: Display when condition is satisfied
D: Display that requires special operations of switches
*2: Display sequence from when the start switch is turned ON to when the standard screen appears depends on the machine
settings and conditions as follows.
W: When engine start lock is ON
X: When engine start lock is OFF
Y: When any defect sensed by the check before start
Z: When any maintenance item is sensed to be near maintenance time or exceeded
REMARK
q For how to operate the operator mode functions, see the Operation and Maintenance Manual.
q For the procedure on the engine start lock function, see "Password setting and canceling manual".
10-102 HD465-8, HD605-8

SERVICE MODE FUNCTION OF MACHINE MONITOR

These functions are not shown usually. A technician can show and set them special operation of switches. These functions are
used for special settings, test, adjust or troubleshoot.
REMARK
For operation procedure of the service mode functions, see TEST AND ADJUST, "SERVICE MODE".
Items available in the service mode are as follows:
Pre-defined Monitoring
Self-define Monitoring
Mechanical Sys Abnormality Record
Abnormality Record
Electrical Sys Abnormality Record
Maintenance Record
Maintenance Mode Setting
Phone Number Entry
Machine Model Select
Option Selection
Unit
Default
Rearview Monitor Setting
KOMTRAX Plus Setting
Auto Idle Stop Timer Fixing
Cylinder Cutout Mode Operation
Active Regeneration for Service
Diagnostic Tests KDPF Memory Reset
Engine Controller Active Fault Clear
Ash in Soot Accumulation Correction
ECMV Automatic Compensation
T/M Initial Learning
T/M Initial Learning Reset
Engine Mode Fixing
Fan Mode Fixing
Adjustment
S/T Pump Swash Plate Fixing
Throttle Limit Check
KTCS Check
Retarder Hoist Controller Memory Reset
KTCS Valve fixing
No-Injection Cranking
HD465-8, HD605-8 10-103

Setting of Loading Start Payload

Setting of Loading End Travel Dist.
Payload offset
Payload Meter Setting Payload Calculation Method
Payload Calculation Compensation
Inclination Angle Sen Compensation
Setting of Range of External Lamps
Manual Snap Shot
Terminal Setting State
KOMTRAX Settings GPS & Communication State
Modem Information
Service Message
10-104 HD465-8, HD605-8

SWITCH PANEL
STRUCTURE OF SWITCH PANEL
INPUT/OUTPUT SIGNALS OF SWITCH PANEL

AMP-6P [OPM]

1 Switch panel power supply (12 V) Input
2 GND (Switch panel power supply) -
3 LIN Input/output
4 Switch panel continuous power supply (5.6 V) Input
5 External start signal (for switch panel) Output
6 Switch panel buzzer Input
HD465-8, HD605-8 10-105

REARVIEW MONITOR
STRUCTURE OF REARVIEW MONITOR
INPUT/OUTPUT SIGNALS OF REARVIEW MONITOR

AMP-12P [RMN1]

2 Power supply return GND -
3 External start signal Input
4 (*1) -
5 Rearview monitor intensity adjustment switch + Input
6 Rearview monitor intensity adjustment switch - Input
7 Gear shift lever R signal Input
8 Monitor intensity selection switch (night mode signal) Input
9 LIN Input/output
10 (*1) -
11 (*1) -
10-106 HD465-8, HD605-8

AMP-8P [RMN2]

1 Rearview camera power supply output Output
2 Rearview camera NTSC signal Input
3 (*1) -
4 (*1) -
5 GND (rearview camera power supply) -
6 (*1) -
7 (*1) -
8 GND (rearview camera shield) -

REARVIEW CAMERA
STRUCTURE OF REARVIEW CAMERA
General view
INPUT/OUTPUT SIGNALS OF REARVIEW CAMERA

CN1 [RVC1]

1 Rearview camera power supply Input
2 Rearview camera NTSC signal Output
3 (*1) -
4 GND (rearview camera power supply) -
HD465-8, HD605-8 10-107

KOMTRAX TERMINAL
STRUCTURE OF KOMTRAX TERMINAL
General view
Model: TC730
1: LED lamp display 4: Machine harness connection (070-12P)

2: GPS antenna connection (Unused) 5: KOMATRAX communication antenna connection
3: Machine harness connection (070-18P)
FUNCTION OF KOMTRAX TERMINAL
q This terminal is a communication device which transmits different information obtained from KOMTRAX Plus via KOM-
TRAX communication antenna.
q The condition of KOMTRAX terminal is shown on the "KOMTRAX Settings" screen in the service mode of the machine
monitor.
q Use of KOMTRAX terminal limited for the countries in which such communication is allowed.
q The terminal has LED lamps and 7-segment lamps used to test and troubleshoot on its display section.
REMARK
q When you start Komtrax operation or change the country where the system is used, you are required to notify Komatsu Ltd.
INPUT AND OUTPUT SIGNALS OF KOMTRAX TERMINAL
070-18P [KOM1A]

1 (*1) -
2 (*1) -
3 (*1) -
4 (*1) -
5 (*1) -
6 Signal to boot-up KOMTRAX terminal Input
7 (*1) -
8 (*1) -
9 External download switch Input
10 CAN1_L (KOMNET/c) Input/output
11 CAN1_H (KOMNET/c) Input/output
12 (*1) -
13 (*1) -
10-108 HD465-8, HD605-8


15 System operation lamp Output
16 (*1) -
17 (*1) -
18 (*1) -
070-12P [KOM1B]

4 (*1) -
5 (*1) -
8 (*1) -
9 (*1) -
10 (*1) -
11 (*1) -
12 (*1) -
HD465-8, HD605-8 10-109

KOMTRAX PLUS CONTROLLER

STRUCTURE OF KOMTRAX PLUS CONTROLLER
General view
1: Machine harness connection (CN-KPS1) 4: USB connection (Unused)

2: Machine harness connection (CN-KPS2) 5: Wireless LAN connection (CN-KPS5)
3: GPS antenna connection 6: Service connector connection (CN-KPS4)
INPUT AND OUTPUT SIGNALS OF KOMTRAX PLUS CONTROLLER

DRC22–50P-04 “KPS1”
Input/output
Pin No. Signal name
signal
1 GND (analog) -
2 GND (analog) -
3 (*1) -
4 (*1) -
5 External download switch Input
6 (*1) -
7 GND (digital) -
8 (*1) -
9 (*1) -
10 (*1) -
11 (*1) -
10-110 HD465-8, HD605-8

Input/output
Pin No. Signal name
signal
12 (*1) -
13 (*1) -
14 longitudinal inclination angle sensor Input
15 Suspension pressure sensor (right front) Input
16 (*1) -
17 (*1) -
18 (*1) -
19 (*1) -
20 (*1) -
21 Suspension pressure sensor (left front) Input
22 Suspension pressure sensor (left rear) Input
23 Suspension pressure sensor (right rear) Input
24 (*1) -
25 (*1) -
26 (*1) -
27 (*1) -
28 (*1) -
29 (*1) -
30 (*1) -
31 (*1) -
32 (*1) -
33 (*1) -
34 (*1) -
35 (*1) -
36 (*1) -
37 (*1) -
38 (*1) -
39 (*1) -
40 (*1) -
41 (*1) -
42 Exhaust temperature sensor Input
43 (*1) -
44 (*1) -
45 External air temperature sensor Input
46 (*1) -
47 (*1) -
48 (*1) -
49 PLM protocol switch (MMS communication) Input
50 PLM protocol switch (Automatic transmission) Input
HD465-8, HD605-8 10-111

DRC22–50P-05 “KPS2”
Input/output
Pin No. Signal name
signal
1 (*1) -
2 (*1) -
11 (*1) -
12 (*1) -
13 (*1) -
14 (*1) -
15 Download indicator outside cab power supply output (12 V) Output
20 (*1) -
21 CAN3_L (External supply) Input/output
22 CAN3_H (External supply) Input/output
23 RS232C RxD (PLM data download) Input
24 (*1) -
25 (*1) -
26 Signal to boot-up KOMTRAX terminal Output
27 Signal during program update program Output
28 (*1) -
29 (*1) -
30 (*1) -
31 CAN1_L (KOMNET/r) Input/output
32 CAN1_H (KOMNET/r) Input/output
33 (*1) -
34 (*1) -
35 GND (RS232C) -
36 (*1) -
37 (*1) -
10-112 HD465-8, HD605-8

Input/output
Pin No. Signal name
signal
38 (*1) -
39 (*1) -
40 (*1) -
41 CAN1_L (KOMNET/c) Input/output
42 CAN1_H (KOMNET/c) Input/output
43 RS232C TxD (PLM data download) Output
44 (*1) -
45 (*1) -
46 PLM external lamp (red) relay Output
47 PLM external lamp (yellow) relay Output
48 PLM external lamp (green) relay Output
49 Sensor power supply (24 V) Output
50 (*1) -
LTWRJS-5EPFFP-LC7002 “KPS5”
Input/output
Pin No. Signal name
signal
1 TX (+) Output
2 TX (-) Output
3 RX (+) Input
4 Ethernet power supply (12 V) Output
5 Ethernet power supply (12 V) Output
6 RX (-) Input
7 GND -
8 GND -
LTWRJS-5EPFFP-LC7002 “KPS4”
Input/output
Pin No. Signal name
signal
1 TX (+) Output
2 TX (-) Output
3 RX (+) Input
4 (*1) -
5 (*1) -
6 RX (-) Input
7 (*1) -
8 (*1) -
HD465-8, HD605-8 10-113

WIRELESS LAN UNIT

STRUCTURE OF WIRELESS LAN UNIT
General view
1: Machine harness connection (CN-WLM) 3: Wireless LAN antenna connection

2: LED lamp display
FUNCTION OF WIRELESS LAN UNIT
q This unit is a communication device which transmits different information obtained from KOMTRAX Plus via wireless LAN
antenna.
q Use of this unit limited for the countries in which such communication is allowed.
q The terminal has LED lamps used for test and troubleshooting on its display section.
REMARK
When operation of the system in Japan, it is required to install a terminal for exclusive use in Japan.
INPUT AND OUTPUT SIGNALS OF WIRELESS LAN UNIT
MPS588.C-8P “WLM”
Input/output
Pin No. Signal name
signal
1 TX (+) Output
2 TX (-) Output
3 RX (+) Input
4 Ethernet power supply (12 V) Input
5 Ethernet power supply (12 V) Input
6 RX (-) Input
7 GND -
8 GND -
10-114 HD465-8, HD605-8

TRANSMISSION CONTROLLER
STRUCTURE OF TRANSMISSION CONTROLLER
General view
FUNCTION OF TRANSMISSION CONTROLLER

The transmission controller has these functions.
q Receives position signal from the gear shift lever, throttle position information from the accelerator pedal, and speed signal
from the transmission. It also receives signals of other switches and sensors, and then sets the transmission to the proper
gear speed automatically.
q Controls the radiator fan to the temperatures of each oil and coolant.
q Outputs the throttle correction command to the engine controller and adjusts the engine speed during the gear shift proce-
dure to reduce the gear shift shock.
q Allows transmission oil flow with the large-capacity pump for charge of the torque converter, when the engine speed is low
and the transmission is at low temperature. It compensates for that pressure with a small-sized pump in other cases to
reduce the loss.
q Speed sensors on the input shaft, middle shaft, and output shaft of the transmission detect slip of the transmission clutch
and protect the transmission when there is hydraulic system trouble.
q Connects to the network and shares information of different types with the controller.
q Receives the machine model selection information (on which machine model the transmission controller is attached) from
the network.
q The self-check function divided for each input and output.
q The self-check function is shown on the machine monitor.
q When a failure is sensed, its contents are transmitted to the network.
q When a failure occurs, it is shown on the machine monitor.
q The substitutive escape function for a failure in the electrical system is installed.
HD465-8, HD605-8 10-115

INPUT AND OUTPUT SIGNALS OF TRANSMISSION CONTROLLER

DEUTSCH-24P [ATC1]

1 Torque converter oil pressure sensor Input
2 Main pressure variable valve operation pressure sensor Input
3 Transmission oil temperature sensor Input
4 GND (Pulse) -
5 (*1) -
6 Gear shift lever position N signal Input
7 Steering and hoist pump oil pressure sensor (optional) Input
8 (*1) -
9 Torque converter oil temperature sensor Input
10 GND (Pulse) -
11 Secondary steering operation signal Input
12 (*1) -
13 Transmission main flow selector valve actuation pressure sensor Input
14 (*1) -
15 Alternator terminal R Input
17 Machine lock-out operation switch 1 (optional) Input
18 AISS switch Input
19 (*1) -
20 (*1) -
21 GND (analog) -
22 Sensor power supply output (5 V) Output
23 Engine starter operation signal Input
24 Machine lock-out operation switch 2 (optional) Input
DEUTSCH-40P (1) [ATC2]

1 (*1) -
2 Fill switch 2nd Input
3 Limp-home switch Input
4 (*1) -
5 Gear shift lever position 5 signal Input
7 Transmission oil filter 1 Input
8 Steering pump lock-out solenoid valve (optional) Output
9 Steering and hoist pump lockout solenoid valve (optional) Output
10-116 HD465-8, HD605-8


10 Radiator fan speed sensor Input
11 (*1) -
12 Fill switch 1st Input
13 Transmission oil filter 2 Input
14 (*1) -
17 (*1) -
18 (*1) -
19 Radiator fan reverse solenoid valve Output
20 Transmission intermediate speed sensor Input
21 Machine lock-out operation lamp (optional) Output
25 Gear shift lever position D signal Input
27 Fill switch High Input
28 Battery relay operation signal Output
29 GND (Pulse) -
30 Transmission output shaft speed sensor Input
31 (*1) -
34 (*1) -
35 Gear shift lever position R signal Input
37 Fill switch Low Input
38 Fill switch 4th Input
39 GND (Pulse) -
40 Transmission input shaft speed sensor Input
DEUTSCH-40P (2) [ATC3]

2 Solenoid power supply (24 V) Input
3 SOL_COM (solenoid GND) -
4 Solenoid power supplies hold relay drive signal Output
HD465-8, HD605-8 10-117


5 ECMV Rev (+) Output
6 ECMV high (+) Output
7 Main flow selector solenoid valve Output
8 (*1) -
9 (*1) -
10 (*1) -
15 ECMV L/U (+) Output
16 ECMV 1st (+) Input
17 (*1) -
18 Radiator fan pump EPC valve Output
19 Fill switch 3rd Input
20 (*1) -
25 Engine start relay output Output
26 ECMV 2nd (+) Output
27 ECMV Low (+) Output
28 (*1) -
29 Fill switch Rev Input
30 (*1) -
35 (*1) Output
36 ECMV 3rd (+) Output
37 ECMV 4th (+) Output
38 Main pressure variable solenoid valve Output
39 (*1) -
40 (*1) -
10-118 HD465-8, HD605-8

RETARDER AND HOIST CONTROLLER

STRUCTURE OF RETARDER AND HOIST CONTROLLER
General view
FUNCTION OF RETARDER AND HOIST CONTROLLER

The retarder and hoist controller has these functions.
Retarder control
Controls the proportion solenoid valves for the rear wheels in accord to the operation angle of the retarder control lever.
KTCS (Komatsu Traction Control System) (optional)

Controls the retarder automatically when any tire slips. This prevents slip of the drive wheels caused by over torque and im-
proves the start and travel performance on soft ground, uphill travel and slopes.
Retarder control for overrun prevention and transmission proper use
Controls the proportion solenoid valves of the rear wheels in accord with the command (analog) of the transmission controller
to operate the retarder by a certain quantity.
Automatic retarder speed control (ARSC)

Controls the solenoid valves to keep the speed set by the automatic retarder speed setting switch during downhill travel to con-
trol the retarder brake power.
Automatic suspension control (optional)

Reference the operation and load conditions, such as empty, loaded, turning, or applied brakes. The automatic suspension
valve switches the suspension force on the front suspension to soft, medium, or hard.
Hoist control
The hoist EPC valve and steering pump solenoid valve control the dump body corresponding to the position of the dump lever.
Automatic secondary steering system

If oil flow in the steering circuit decreases below the specified value, the secondary steering pump automatically operates.
Brake lamp control

Turns on the brake lamp when the retarder or the foot brake is operated.
HD465-8, HD605-8 10-119

Communication of network information

Communicates the information and warning on control with other controllers through the network.
INPUT AND OUTPUT SIGNALS OF RETARDER AND HOIST CONTROLLER
DEUTSCH-24P [BRC1]

1 Acceleration sensor (for KTCS, optional) Input
2 (*1) -
3 (*1) -
4 GND (analog) -
5 Rudder angle sensor Input
6 Dump body position sensor Input
7 Secondary brake hydraulic sensor Input
8 Retarder control lever Input
9 Steering oil temperature sensor Input
10 GND (Pulse) -
11 (*1) -
12 Suspension hydraulic sensor (rear right) Input
13 KTCS hydraulic sensor (rear right) (optional) Input
14 Suspension hydraulic sensor (rear left) Input
17 (*1) -
18 Hoist lever (sub) Input
19 Retarder oil pressure sensor (rear) Input
20 Retarder oil temperature sensor (rear) Input
23 ARSC setting switch Input
24 Hoist lever (main) Input
DEUTSCH-40P (1) [BRC2]

2 (*1) -
3 Validation switch 2 Input
4 (*1) -
5 Parking brake oil pressure sensor Input
6 Inclination angle sensor Input
7 (*1) -
8 Front brake cut valve Output
10-120 HD465-8, HD605-8


9 Automatic suspension solenoid 2 (optional) Output
10 Wheel speed sensor (rear left) Input
11 (*1) -
12 Service brake operation switch Input
13 Validation switch 1 Input
14 (*1) -
15 Secondary S/T oil pressure sensor Input
16 KTCS hydraulic sensor (rear left) (optional) Input
17 (*1) -
18 Steering pump selector valve Output
19 Automatic suspension solenoid 1 (optional) Output
20 Wheel speed sensor (rear right) Input
21 (*1) -
25 Steering oil pressure sensor Input
26 Accumulator oil pressure sensor (rear) Input
27 (*1) -
28 KTCS shutoff valve Output
29 GND (Pulse) -
30 (*1) -
31 (*1) -
34 (*1) -
35 (*1) -
36 Accumulator oil pressure sensor (front) Input
37 Steering speed sensor (optional) Input
38 Memory clear switch Input
39 GND (Pulse) -
40 (*1) -
DEUTSCH-40P (2) [BRC3]

HD465-8, HD605-8 10-121


4 (*1) -
5 Hoist EPC valve Output
6 KTCS EPC solenoid (rear left) Output
7 (*1) -
8 Hoist selection valve Output
9 (*1) -
10 Start switch C (engine start) Input
15 Brake lamp operation relay (center) Output
16 KTCS EPC solenoid (rear right) Output
17 Brake cooling valve Output
18 Hoist lever kick-out solenoid valve Output
19 (*1) -
20 Secondary steering switch Input
25 Brake lamp operation relay (right/left) Output
26 (*1) -
27 (*1) -
28 Automatic secondary steering relay Output
29 Parking brake solenoid signal Input
30 Front brake cut switch Input
31 GND (continuous power supply) Input
35 Parking brake inter-lock relay Output
36 (*1) -
37 Retarder proportion solenoid valve (rear) Output
38 (*1) -
39 (*1) -
40 (*1) -
10-122 HD465-8, HD605-8

MONITOR CONTROLLER
STRUCTURE OF MONITOR CONTROLLER
General view
INPUT AND OUTPUT SIGNALS OF MONITOR CONTROLLER

AMP-81P [MCM1] (for monitor controller)
Input/output
Pin No. Signal name
signal
5 (*1) -
6 Alternator R signal Input
7 (*1) -
8 Fuel level sensor Input
9 GND (analog) -
10 Dimmer switch Input
11 Start switch C signal Input
12 Seat belt Input
13 GND (digital) -
14 High beam condition Input
15 Left turn signal Input
HD465-8, HD605-8 10-123

Input/output
Pin No. Signal name
signal
16 Right turn signal Input
17 (*1) -
18 Head lamp relay (high beam) Output
19 Personal code relay Output
20 Buzzer Output
21 (*1) -
22 Night light switch power supply Output
23 (*1) -
25 (*1) -
26 (*1) -
27 (*1) -
28 (*1) -
29 (*1) -
30 Selection of unit Input
31 Engine secondary shutdown switch Input
32 (*1) -
33 Monitor intensity selection switch Input
34 Lamp switch Input
35 Engine pre-heating relay Input
36 (*1) -
37 (*1) -
38 (*1) -
39 (*1) -
40 (*1) -
41 GND (Night light switch power supply) -
42 (*1) -
44 (*1) -
45 (*1) -
46 (*1) -
47 (*1) -
48 Cooling water switch Input
49 Hydraulic oil filter restriction switch Input
50 Brake cooling oil filter restriction switch Input
51 (*1) -
52 (*1) -
53 Air cleaner restriction switch Input
10-124 HD465-8, HD605-8

Input/output
Pin No. Signal name
signal
54 Door switch Input
55 (*1) -
56 (*1) -
58 Parking brake lamp switch Output
59 (*1) -
60 Power supply for gear shift lever lamp Output
61 (*1) -
63 (*1) -
64 (*1) -
65 (*1) -
66 (*1) -
67 (*1) -
68 (*1) -
69 Engine low oil level switch Input
70 (*1) -
71 (*1) -
72 (*1) -
73 (*1) -
74 (*1) -
75 (*1) -
76 (*1) -
77 (*1) -
78 (*1) -
79 GND (Power supply for gear shift lever lamp) -
80 (*1) -
81 (*1) -
AMP-40P [MCM2] (for monitor controller)
Input/output
Pin No. Signal name
signal
82 Switch panel buzzer Output
83 (*1) -
84 (*1) -
85 (*1) -
86 (*1) -
87 (*1) -
HD465-8, HD605-8 10-125

Input/output
Pin No. Signal name
signal
88 (*1) -
90 (*1) -
91 LED unit power supply (5 V) Output
92 (*1) -
93 (*1) -
84 (*1) -
95 (*1) -
96 (*1) -
98 Switch panel continuous power supply (5.6 V) Output
99 GND (power supply for switch panel and LED unit) -
100 (*1) -
101 (*1) -
102 (*1) -
103 (*1) -
104 (*1) -
106 External start signal (for switch panel) Input
107 Switch panel and LED unit power supply output (12 V) Output
108 LIN Input/output
109 (*1) -
110 (*1) -
111 (*1) -
112 CAN1 terminating resistor -
114 (*1) -
115 (*1) -
116 (*1) -
117 (*1) -
118 (*1) -
119 (*1) -
120 (*1) -
121 (*1) -
10-126 HD465-8, HD605-8

SAE-8P [MCM3] (for LC unit)
Input/output
Pin No. Signal name
signal
1 LC unit LVDS + Output
2 LC unit LVDS - Output
3 GND (LC unit power supply) -
4 LC unit backlight adjustment Output
5 LC unit power supply Output
6 LC unit ON/OFF control Output
7 LC unit backlight ON/OFF control Output
8 LC unit temperature sensor Output
HD465-8, HD605-8 10-127

ENGINE CONTROLLER
STRUCTURE OF ENGINE CONTROLLER A
General view
FUNCTION OF ENGINE CONTROLLER A

q Engine controller (CM2250) is used, which was developed by Komatsu and Cummins.
q The engine controller calculates input signals from sensors, and controls outputs that control the engine.
q The engine controller commonly communicates information with other controllers on the machine through the network
(CAN) and controls the engine and machine correctly.
q Since the engine controller is installed on the engine, it’s serviceable.
q To reduce the vibration, it is installed on rubber mounts.
INPUT AND OUTPUT SIGNALS OF ENGINE CONTROLLER A
Delphi96Pin (J1 connector)
Pin No. Signal name Input/output

1 Injector #1 (-) Ground/Shield/Return
4 (*1) -
5 Fuel doser A (+) Output
6 Fuel doser solenoid valve 2-A Output
7 Fuel feed pump-A Output
8 Fuel doser solenoid valve 1-A Output
9 (*1) -
10-128 HD465-8, HD605-8


10 (*1) -
11 (*1) -
12 (*1) -
13 EGR valve solenoid (+) Output
14 PCV2-A (+) Output
15 (*1) -
16 Turbocharger speed (-) Ground/Shield/Return
17 Turbocharger speed (+) Input
18 Engine Backup speed sensor-A Input
19 (*1) -
20 (*1) -
21 (*1) -
22 (*1) -
23 PCV1-A (+) Output
24 PCV1-A (-) Ground/Shield/Return
25 Injector #1 (+) Output
28 (*1) -
29 Fuel doser A (-) Ground/Shield/Return
30 GND Ground/Shield/Return
31 Engine NE speed sensor Input
32 Mass airflow sensor Input
33 (*1) -
34 (*1) -
35 (*1) -
36 (*1) -
37 Dosing fuel pressure sensor-A Input
38 (*1) -
39 (*1) -
40 (*1) -
41 (*1) -
42 (*1) -
43 (*1) -
44 Ambient pressure sensor Input
45 Charge pressure sensor Input
46 (*1) -
47 (*1) -
48 PCV2-A (-) Ground/Shield/Return
HD465-8, HD605-8 10-129


52 (*1) -
53 (*1) -
59 (*1) -
60 (*1) -
61 Intake air temperature sensor Input
62 Charge pressure sensor Input
63 Crankcase pressure sensor Input
64 (*1) -
65 (*1) -
66 (*1) -
67 VGT position sensor Input
68 (*1) -
69 Datalink2 (+) (Engine controller communication) Communication
70 Datalink3 (+) (KOMNET/r) Communication
71 (*1) -
72 (*1) -
76 EGR valve solenoid (-) Ground/Shield/Return
77 (*1) -
78 Sensor 5 V power supply Power supply
83 Coolant temperature sensor Input
84 (*1) -
85 Engine oil pressure sensor Input
86 (*1) -
87 Common rail pressure sensor Input
10-130 HD465-8, HD605-8


88 EGR valve lift sensor Input
89 (*1) -
90 Engine oil temperature sensor Input
91 (*1) -
92 (*1) -
93 Datalink2 (-) (Engine controller communication) Communication
94 Datalink3 (-) (KOMNET/r) Communication
95 (*1) -
96 (*1) -

1 Power supply (+24 V, continuous) Power supply
2 VGT Solenoid (-) Ground/Shield/Return
3 (*1) -
4 (*1) -
5 ACC (Key SW) Input
6 (*1) -
7 (*1) -
10 Throttle sensor Input
11 (*1) -
12 (*1) -
13 (*1) -
14 (*1) -
15 (*1) -
16 (*1) -
17 (*1) -
18 (*1) -
19 (*1) -
20 (*1) -
21 Datalink4-B (+) (Sensor controller) Communication
22 Datalink1 (+) (KOMNET/c) Communication
23 (*1) -
24 (*1) -
HD465-8, HD605-8 10-131


29 (*1) -
30 (*1) -
31 (*1) -
34 (*1) -
35 (*1) -
36 (*1) -
37 (*1) -
38 (*1) -
39 (*1) -
40 (*1) -
41 KDPF differential pressure sensor-A Input
42 KDPF outlet pressure sensor-A Input
(*1): Machine equipped with fuel control dial
43 -
Idle validation switch 2: Machine with accelerator pedal
(*1): Machine equipped with fuel control dial
44 -
Idle validation switch 1: Machine with accelerator pedal
45 Datalink4-A (-) (Sensor controller) Communication
47 (*1) -
49 Power GND Ground/Shield/Return
53 (*1) -
54 (*1) -
55 (*1) -
56 (*1) -
57 (*1) -
58 (*1) -
59 (*1) -
60 (*1) -
63 (*1) -
64 (*1) -
10-132 HD465-8, HD605-8


65 (*1) -
66 (*1) -
67 (*1) -
68 (*1) -
69 (*1) -
70 (*1) -
71 (*1) -
72 (*1) -
74 (*1) -
75 Intake air heater relay Output
76 (*1) -
77 (*1) -
78 (*1) -
79 (*1) -
80 VGT Solenoid (+) Output
81 (*1) -
82 (*1) -
83 (*1) -
84 (*1) -
85 (*1) -
86 (*1) -
87 (*1) -
88 (*1) -
89 HARNESS KEY1 Input
90 (*1) -
91 (*1) -
92 (*1) -
93 (*1) -
94 (*1) -
95 (*1) -
96 (*1) -
HD465-8, HD605-8 10-133

STRUCTURE OF ENGINE CONTROLLER B

General view
FUNCTION OF ENGINE CONTROLLER B

q Engine controller (CM2250) is used, which was developed by Komatsu and Cummins.
q The engine controller calculates input signals from sensors, and controls outputs that control the engine.
q The engine controller commonly communicates information with other controllers on the machine through the network
(CAN) and controls the engine and machine correctly.
q Since the engine controller is installed on the engine, it’s serviceable.
q To reduce the vibration, it is installed on rubber mounts.
INPUT AND OUTPUT SIGNALS OF ENGINE CONTROLLER B

1 (*1) -
2 (*1) -
3 (*1) -
4 (*1) -
5 Fuel doser-B (+) Output
6 Fuel doser solenoid valve 2-B Output
7 Fuel feed pump-B Output
8 Fuel doser solenoid valve 1-B Output
9 (*1) -
10 (*1) -
10-134 HD465-8, HD605-8


11 (*1) -
12 (*1) -
13 (*1) -
14 PCV2-B (+) Output
15 (*1) -
16 (*1) -
17 (*1) -
18 Engine Backup speed sensor-B Input
19 (*1) -
20 (*1) -
21 (*1) -
22 (*1) -
23 PCV1-B (+) Output
24 PCV1-B (-) Ground/Shield/Return
25 (*1) -
26 (*1) -
27 (*1) -
28 (*1) -
29 Fuel doser-B (-) Ground/Shield/Return
31 Engine NE speed sensor Input
32 (*1) -
33 (*1) -
34 (*1) -
35 (*1) -
36 (*1) -
37 Dosing fuel pressure sensor B Input
38 (*1) -
39 (*1) -
40 (*1) -
41 (*1) -
42 (*1) -
43 (*1) -
44 (*1) -
45 (*1) -
46 (*1) -
47 (*1) -
48 PCV2-B (-) Ground/Shield/Return
49 (*1) -
HD465-8, HD605-8 10-135


50 (*1) -
51 (*1) -
52 (*1) -
53 (*1) -
56 (*1) -
58 (*1) -
59 (*1) -
60 (*1) -
61 (*1) -
62 (*1) -
63 (*1) -
64 (*1) -
65 (*1) -
66 (*1) -
67 (*1) -
68 (*1) -
69 Datalink2 (+) (Engine controller communication) Communication
70 (*1) -
71 (*1) -
72 (*1) -
73 (*1) -
74 (*1) -
75 (*1) -
76 (*1) -
77 (*1) -
79 (*1) -
80 (*1) -
82 (*1) -
83 (*1) -
84 (*1) -
85 (*1) -
86 (*1) -
87 (*1) -
88 (*1) -
10-136 HD465-8, HD605-8


89 (*1) -
90 (*1) -
91 (*1) -
92 (*1) -
93 Datalink2 (-) (Engine controller communication) Communication
94 (*1) -
95 (*1) -
96 (*1) -

2 (*1) -
3 (*1) -
4 (*1) -
5 ACC (Key SW) Input
6 (*1) -
7 (*1) -
9 (*1) -
10 (*1) -
11 (*1) -
12 (*1) -
13 (*1) -
14 (*1) -
15 (*1) -
16 (*1) -
17 (*1) -
18 (*1) -
19 (*1) -
20 (*1) -
21 Datalink4-B (+) (Sensor controller) Communication
23 (*1) -
24 (*1) -
HD465-8, HD605-8 10-137


29 (*1) -
30 (*1) -
31 (*1) -
33 (*1) -
34 (*1) -
35 (*1) -
36 (*1) -
37 (*1) -
38 (*1) -
39 (*1) -
40 (*1) -
41 KDPF differential pressure sensor-B Input
42 KDPF outlet pressure sensor-B Input
43 (*1) -
44 (*1) -
45 Datalink4-B (-) (Sensor controller) Communication
47 (*1) -
53 (*1) -
54 (*1) -
55 (*1) -
56 (*1) -
57 (*1) -
58 (*1) -
59 (*1) -
60 (*1) -
61 (*1) -
63 (*1) -
64 (*1) -
65 (*1) -
66 (*1) -
10-138 HD465-8, HD605-8


67 (*1) -
68 (*1) -
69 (*1) -
70 (*1) -
71 (*1) -
72 (*1) -
74 (*1) -
75 (*1) -
76 (*1) -
77 (*1) -
78 (*1) -
79 (*1) -
80 (*1) -
81 (*1) -
82 (*1) -
83 (*1) -
84 (*1) -
85 (*1) -
86 (*1) -
87 (*1) -
88 (*1) -
89 (*1) -
90 HARNESS KEY2 Input
91 (*1) -
92 (*1) -
93 (*1) -
94 (*1) -
95 (*1) -
96 (*1) -
HD465-8, HD605-8 10-139

ABS CONTROLLER
STRUCTURE OF ABS CONTROLLER
FUNCTION OF ABS CONTROLLER

q ABS controller calculates the wheel speed and pseudo machine travel speed according to the signals from the wheel speed
sensors attached to each wheel, then it sends control signals to the control valves of wheels that have tendency to lock or
are skidding.
When the system is defective, the ABS controller displays failure codes using the built-in diagnostic function. At the same
time, ABS stops the system operation and works as a conventional brake.
INPUT AND OUTPUT SIGNALS OF ABS CONTROLLER
CN1

1 ABS control valve pressure (rear left) Input
2 ABS cut valve pressure sensor Input
3 (*1) -
4 GND_SIG_A -
5 (*1) -
6 (*1) -
7 ABS control valve pressure (rear right) Input
8 (*1) -
9 (*1) -
10 GND_SIG_D -
11 (*1) -
12 (*1) -
10-140 HD465-8, HD605-8


13 ABS control valve pressure (front left) Input
14 (*1) -
16 PWR_OUT_SENS Output
17 ABS cut valve pressure SW (rear) Input
18 (*1) -
19 ABS control valve pressure (front right) Input
20 (*1) -
21 GND_SIG_A -
22 PWR_OUT_5V_0 Output
23 ABS cut valve pressure SW (front) Input
24 Secondary steering operation state Input
CN2

1 PWR_OUT_5V_1 Output
2 (*1) -
3 (*1) -
4 (*1) -
5 (*1) -
6 (*1) -
7 (*1) -
8 (*1) -
9 ABS cut valve (rear) Output
10 (*1) -
11 (*1) -
12 (*1) -
13 (*1) -
14 (*1) -
15 (*1) -
16 (*1) -
17 (*1) -
18 (*1) -
19 ABS cut valve (front) Output
20 (*1) -
21 (*1) -
22 COM_CAN_L_0 Input/output
23 COM_CAN_L_1 Input/output
24 PWR_CTR_EXT Input
HD465-8, HD605-8 10-141


25 (*1) -
26 (*1) -
27 (*1) -
28 (*1) -
29 GND_SIG_P -
30 Wheel speed (front left) Input
31 COM_CAN_SH -
32 COM_CAN_H_0 Input/output
33 COM_CAN_H_1 Input/output
34 (*1) -
35 Starter C terminal Input
36 (*1) -
37 (*1) -
38 (*1) -
39 GND_SIG_P -
40 Wheel speed (front right) Input
CN3

1 PWR_IN_BATT Input
2 PWR_IN_BRY Input
3 GND_ACT Input
4 (*1) -
5 (*1) -
6 ABS control valve (rear right) Output
7 (*1) -
8 (*1) -
9 (*1) -
10 (*1) -
11 PWR_IN_BATT Input
12 PWR_IN_BRY Input
13 GND_ACT Input
14 PWR_CTR_KEY Input
15 (*1) -
16 ABS control valve (rear left) Output
17 (*1) -
18 (*1) -
19 (*1) -
20 (*1) -
10-142 HD465-8, HD605-8


21 GND_PWR Input
22 PWR_IN_BRY Input
23 GND_ACT Input
24 PWR_CTR_KEY Input
25 (*1) -
26 (*1) -
27 ABS control valve (front right) Output
28 (*1) -
29 (*1) -
30 (*1) -
31 GND_PWR Input
32 GND_PWR Input
33 GND_PWR Input
34 SYS_BUSY Output
35 (*1) -
36 (*1) -
37 ABS control valve (front left) Output
38 (*1) -
39 (*1) -
40 (*1) -
HD465-8, HD605-8 10-143

ACCELERATOR PEDAL
STRUCTURE OF ACCELERATOR PEDAL
1: Pedal 3: Sensor
2: Connector
FUNCTION OF ACCELERATOR PEDAL
This pedal is installed on the upper surface of the floor. It sends acceleration signal and idle signal in reference to the angle of
accelerator pedal.
Acceleration signal
Sensor senses the quantity of movement of the accelerator pedal, and it sends the adjusted voltage from pin No.2.
Idling validation signal

Sensor senses the condition of accelerator pedal operation. When the accelerator pedal is released, it sends the signal from
pin No.5. When the accelerator pedal is depressed, it sends the signal from pin No.6.
10-144 HD465-8, HD605-8

GEAR SHIFT LEVER

STRUCTURE OF GEAR SHIFT LEVER
General view
1: Lever 3:Connector
2: Lock button
HD465-8, HD605-8 10-145

RETARDER CONTROL LEVER

STRUCTURE OF RETARDER CONTROL LEVER
General view
1: Lever 2: Potentiometer
FUNCTION OF RETARDER CONTROL LEVER
The retarder lever has a manual potentiometer and lever validation switches 1 and 2. When the lever is operated, the potenti-
ometer turns and sends a voltage value corresponding to the lever operation angle of the retarder.
In addition, the lever validation switches sends the ON/OFF information of the lever position to the retarder and hoist controller.
10-146 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION HYDRAULIC SYSTEM DIAGRAM
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM DIAGRAM
1: Steering and hoist pump 6: Self-pressure decompression valve, hoist EPC valve
2: Hoist cylinder 7: Radiator fan pump
3: Hoist valve 8: Cross-over relief valve
4: Hydraulic tank 9: Fan motor
5: Steering and hoist filter
HD465-8, HD605-8 10-147

HYDRAULIC SYSTEM COMPONENTS 10 STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM COMPONENTS

HYDRAULIC TANK
STRUCTURE OF HYDRAULIC TANK
General view
1: Hydraulic tank oil level gauge 6: Strainer

2: Breather (2) 7: Brake tank drain plug
3: Spring 8: Hydraulic tank drain plug
4: Bypass valve 9: Brake tank oil level gauge
5: Element
10-148 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION HYDRAULIC SYSTEM COMPONENTS
STEERING AND HOIST PUMP

STRUCTURE OF STEERING AND HOIST PUMP
General view
P1F: Pump discharge port PENF: Control pressure plug

P1LF: Pump pressure input port PENR: Control pressure plug
P1LR: Pump pressure input port PLSF: Load pressure input port
P1R: Pump discharge port PLSF: Load pressure input port
PD2F: Drain plug POPF: Control source pressure input port
PD2R: Drain plug POPF: Control source pressure input port
PDF: Drain port PSF: Pump suction port
PDR: Drain port PSR: Pump suction port
1: Pump body 3: Air bleed
2: Servo valve
HD465-8, HD605-8 10-149

Section view
1: Bearing 11: Servo piston

2: Impeller 12: Shoe retainer
3: Bolt 13: End cap
4: Bolt 14: Valve plate
5: Plate 15: Cylinder block
6: Coupling 16: Piston
7: Shaft 17: Shoe
8: Oil seal 18: Rocker cam
9: Sleeve 19: Case
10: Spring 20: Ball retainer
10-150 HD465-8, HD605-8

Structure
q Cylinder block (6) is held on shaft (1) through spline (a). Shaft (1) is held on the front and rear bearings.
q The point of piston (5) shape is a concave sphere and is crimped with shoe (4). Piston (5) and shoe (4) makes a spherical
bearing.
q Rocker (3) is held by case (2) and ball retainer (9), and has flat surface (A). Shoe (4) is always pushed against this surface
while it slides in a circular pattern. Shoe (4) delivers high pressurized oil, and slides by the set pressure bearing.
q Piston (5) moves in the axial direction in each cylinder chamber of cylinder block (6).
q Cylinder block (6) turns with the valve plate (7) while it seals the pressurized oil.
q The oil pressure is balanced correctly on this surface.
q The pressurized oil is drawn in and released from each cylinder chamber in cylinder block (6) through valve plate (7).
FUNCTION OF STEERING AND HOIST PUMP
q This pump converts the rotation of the engine transmitted by a shaft into hydraulic pressure and releases pressurized oil
corresponding to the load.
q It is possible to change the discharge volume by a change of the swash plate angle.
OPERATION OF STEERING AND HOIST PUMP
Operation of pump
1. Cylinder block (6) turns together with shaft (1) and shoe (4) slides
on plane (A).
2. Rocker cam (3) pivots on ball retainer (9), and corresponding
angle (a) between middle line (X) of rocker cam (3) and the axis
of cylinder block (6) changes.
3. Angle (a) is specified as swash plate angle.
HD465-8, HD605-8 10-151

4. While angle (a) is made between middle line (X) of the rocker
cam (3) and the axis of cylinder block (6), flat surface (A) work as
a cam for shoe (4).
5. Piston (5) slides in cylinder block (6) and a difference is made
between volumes (E) and (F) in cylinder block (6).
6. Oil quantity of (F)-(E) for each piston (5) is drawn in and
discharged.
7. Pressurized oil is discharged while cylinder block (6) turns and
the volume of chamber (E) decreases.
8. Pressurized oil is drawn in as the volume of chamber (F)
increases.
9. When middle line (X) of the rocker cam (3) matches the axis of
cylinder block (6) (the swash plate angle is zero). The difference
between volumes (E) and (F) in cylinder block (6) is zero.
10. Suction and discharge of pressurized oil is not performed in this
step. The pump does not produce oil pressure in this step. (Angle
of swash plate never becomes zero)
11. The pump released volume is in proportion to swash plate angle
(a).
Control of released volume

1. If swash plate angle (a) becomes larger, the difference in
volumes (E) and (F) becomes larger and the released volume
increases.
2. Swash plate angle (a) changes by servo piston (11).
3. Servo piston (11) moves linearly corresponding to the signal
pressure from the PC and LS valves.
4. This linear movement is transmitted to rocker cam (3).
5. Rocker cam (3) held on ball retainer (9) slides around ball
retainer (9).
10-152 HD465-8, HD605-8

SERVO VALVE OF STEERING AND HOIST PUMP

STRUCTURE OF SERVO VALVE OF STEERING AND HOIST PUMP
General view
P1: Pump released pressure port T: Drain port

PE: Control pressure output port
HD465-8, HD605-8 10-153

Section view
PA: Pump pressure input PE: Control piston pressure

PPL: CO valve output pressure PLS: LS pressure input
T: Drain PPLS: LS pump pressure input
1: Plug 9: Piston
2: Spring 10: Nut
3: Retainer 11: Plate
4: Seat 12: Plug
5: Spool 13: Spring
6: Sleeve 14: Seat
7: Piston 15: Spool
8: Seal 16: Plug
10-154 HD465-8, HD605-8

LS VALVE
LS
Abbreviation for Load Sensing
STRUCTURE OF LS VALVE
PA: Pump pressure input PPL: PC valve output pressure

PE: Control piston pressure PPLS: LS pump pressure input
PLS: LS pressure input T: Drain
1: Nut 5: Seat
2: Plate 6: Spool
3: Plug 7: Plug
4: Spring
FUNCTION OF LS VALVE
q The LS valve controls the pump release volume corresponding to the travel of the control lever, or the flow required by the
actuator.
q The LS valve senses the flow rate necessary by the actuator from the different pressure (ΔPLS) between inlet pressure
(PPLS) and outlet pressure (PLS) of the control valve and controls pump release volume (Q). [(PPLS) is named LS pump
pressure, (PLS) the LS pressure, and (ΔPLS) the LS differential pressure]
q Therefore, pressure loss [= LS differential pressure (ΔPLS)], which occurs when the oil flows through the hole in the control
valve spool, is sensed, and pump release volume (Q) is controlled to maintain the pressure loss at a constant level. Through
this operation, the pump can supply the proper volume of oil as required by the actuator.
q Pump release pressure (PP), LS pump pressure (PPLS), and LS
pressure (PLS) are transmitted to LS valve. The relation between
LS differential pressure (ΔPLS) and pump release volume (Q)
changes as shown in the figure on the right.
HD465-8, HD605-8 10-155

CO VALVE
CO
Abbreviation for Cut Off
STRUCTURE OF CO VALVE
PA: Pump pressure input T: Drain

PPL: CO valve output pressure
1: Plug 6: Sleeve
2: Spring 7: Piston
3: Retainer 8: Seal
4: Seat 9: Piston
5: Spool
FUNCTION OF CO VALVE
q The CO (cut off) valve minimizes the pump swash plate angle to prevent pressure increase and protect the circuit when the
pump pressure in the hydraulic circuit is the highest.
q As the pump swash plate angle is minimized, pump torque ab-
sorption is reduced and the fuel consumption is improved.
10-156 HD465-8, HD605-8

OPERATION OF CO VALVE
Effect of spring
The spring force of spring (2) in CO valve determined by the pump release pressure (PA).
Operation when pump pressure (PA) is low (load is light)

(Fig. 1)
1. The push force of spool (5) is decreased and spool (3) is moved a small quantity to the right (Fig. 1). At this time, port (C)
is connected to port (D) and the pressure introduced in LS valve becomes drain pressure (PT).
2. Ports (F) and (G) of LS valve are connected. As a result, the pressure in port (J) becomes drain pressure (PT) and servo
piston (6) moves to the left.
3. Therefore, the pump released volume is increased.
HD465-8, HD605-8 10-157

Operation when pump pressure (PA) is high (load is heavy)

(Fig. 2)
1. The push force of spool (5) is increased and spool (3) sits on the position small quantify to the left (Fig. 2). At this time, port
(C) is connected to port (B) and the pressure introduced in LS valve becomes pump pressure (PA).
2. Ports (F) and (G) of LS valve are connected. As a result, the pressure in port (J) becomes pump pressure (PA) and servo
piston (6) moves to the right.
3. Therefore, the pump released volume is decreased.
10-158 HD465-8, HD605-8

POWER TRAIN AND BRAKE COOLING DUPLEX PUMP

STRUCTURE OF POWER TRAIN AND BRAKE COOLING DUPLEX PUMP
A: From transmission case C: To transmission filter

B: To transmission filter
1: Power train and brake cooling pump 2: Power train and brake cooling pump
SPECIFICATIONS OF POWER TRAIN AND BRAKE COOLING DUPLEX PUMP
Power train and brake cooling pump
Model: SAR (3)72+(2)32
Type: Gear pump
Theoretical released volume: 72.0+32.0 cm3/rev
Max. released pressure: 2.94 MPa {30 kg/cm2}
Max. speed: 2500 rpm
FUNCTION OF POWER TRAIN AND BRAKE COOLING DUPLEX PUMP
q The power train and brake cooling duplex pump is installed on the bottom of PTO case and operated by engine power.
q The power train and brake cooling duplex pump draws in oil collected in the transmission through a strainer, and sends it
to the power train and brake cooling circuit.
HD465-8, HD605-8 10-159

BRAKE COOLING, CONTROL TRIPLE PUMP

STRUCTURE OF BRAKE COOLING, CONTROL TRIPLE PUMP
A: To accumulator charge valve D: From brake oil filter

B: To brake cooling valve E: From transmission case
C: To brake cooling valve F: From transmission case
1: Brake control pump 3: Brake cooling pump
2: Brake cooling pump
SPECIFICATIONS OF BRAKE COOLING, CONTROL TRIPLE PUMP
Brake control pump
Model: SAR (1)25
Type: Gear pump
Theoretical released volume: 25.7 cm3/rev
Brake cooling pump
Model: SAR(3)100+100
Type: Gear pump
Theoretical released volume: 100.5+100.5 cm3/rev
10-160 HD465-8, HD605-8

FUNCTION OF BRAKE COOLING, CONTROL TRIPLE PUMP

q The brake cooling, control three pump is installed on the upper part of PTO case and operated by engine power.
q The power train, control three pump draws in oil collected in the transmission and brake system tank through a strainer,
and sends it to the brake cooling and brake control circuit.
HD465-8, HD605-8 10-161

HOIST VALVE
STRUCTURE OF HOIST VALVE
Section view
10-162 HD465-8, HD605-8

A1: To hoist cylinder bottom PA: From EPC valve (LOWER, FLOAT)
ADT: Adjustment screw PB: From EPC valve (RAISE)
B1: To hoist cylinder head T: To hydraulic tank
P: From demand valve
1: Retainer 7: Relief valve
2: Spool 8: Check valve
3: Valve body 9: Spool return spring (LOWER)
4: Retainer 10: Spool return spring (FLOAT)
5: Retainer 11: Spool return spring (RAISE)
6: Retainer 12: Check valve spring
HD465-8, HD605-8 10-163

OPERATION OF HOIST VALVE

When hoist valve is operated in HOLD position
1. The pressurized oil from the demand valve flows in chamber (C). The routing to the hoist cylinder is blocked with the hoist
spool (2). Since the routing from change (C) to chamber (D) is open, the pressurized oil flows through chamber (D) to the
tank.
2. Since the port to the hoist cylinder is blocked on the bottom and head sides, the hoist cylinder is set at this position.
10-164 HD465-8, HD605-8

When hoist valve is operated in RAISE position
1. If the lever in the cab is set to RAISE position, the pressurized oil from the hoist EPC valve moves the hoist spool (2) to the
left.
2. The pressurized oil flows through chamber (C) to open load check valve (8) and flows in chamber (A).
3. The pressurized oil flows through chamber (A) into the hoist cylinder bottom to extend the hoist cylinder and raise the dump
body.
4. Therefore, the pressurized oil returns from the head side flows through chambers (B) and (D) to the tank.
HD465-8, HD605-8 10-165

When hoist valve is operated in FLOAT position
1. If the lever in the cab is set to FLOAT position, the pressurized oil from the hoist EPC valve moves the hoist spool (2) to
the right.
2. Chamber (C), chamber (D), and chamber (B) are connected. And chamber (A), chamber (H), and chamber (D) are also
connected.
3. The pressurized oil from the demand valve flows through chambers (C) and (B) to the hoist cylinder. It also flows through
chambers (C) and (D) to the tank.
4. Since the bottom end and head end of the hoist cylinder are connected to the tank by the hoist valve, the hoist cylinder is
free.
10-166 HD465-8, HD605-8

When hoist valve is operated in LOWER position
1. If the lever in the cab is moved from FLOAT position to LOWER position, the pressurized oil from the hoist EPC valve moves
the hoist spool (2) more to the right from FLOAT position.
2. The pressurized oil flows through chamber (C) to open check valve (8) and flows in chamber (B).
3. The pressurized oil flows through chamber (B) into the hoist cylinder head to retract the hoist cylinder and lower the dump
body.
4. Therefore, the pressurized oil returns from the head end of the hoist cylinder flows through chambers (A) and (H) to the
tank.
5. When you lower dump body, the output pressure of the hoist EPC valve increases above the cracking pressure of the pilot
check valve. The oil from chamber (H) returns to the tank from chamber (D) and from hoist EPC valve.
HD465-8, HD605-8 10-167

POWER TRAIN DIAGRAM 10 STRUCTURE AND FUNCTION
POWER TRAIN SYSTEM

POWER TRAIN DIAGRAM
1: Engine 9: Front drive shaft

2: Steering and hoist pump 10: Output shaft
3: Brake cooling control triple pump 11: Parking brake
4: PTO 12: Tire
5: Rear drive shaft 13: Differential gear
6: Torque converter 14: Drive shaft
7: Radiator fan pump 15: Rear brake
8: Power train and brake cooling duplex pump 16: Final drive
10-168 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION TRANSMISSION CONTROL SYSTEM
TRANSMISSION CONTROL SYSTEM

TRANSMISSION CONTROL SYSTEM DIAGRAM
HD465-8, HD605-8 10-169

TRANSMISSION CONTROL SYSTEM 10 STRUCTURE AND FUNCTION
1. Monitor controller 23. Radiator fan speed sensor

2. Retarder and hoist controller 24. Transmission main pressure variable valve operation
3. Engine controller pressure sensor
4. KOMTRAX Plus controller 25. Alternator terminal R
5. ECMV fill switch 1st 26. Transmission oil filter restriction sensor 2
6. ECMV fill switch 2nd 27. Transmission oil filter restriction sensor 1
7. ECMV fill switch 3rd 28. Transmission output speed sensor
8. ECMV fill switch 4th 29. Transmission middle shaft speed sensor
9. ECMV fill switch High 30. Transmission input speed sensor
10. ECMV fill switch Low 31. Transmission oil temperature sensor
11. ECMV fill switch Rev 32. Torque converter oil temperature sensor
12. ECMV fill switch Lock-up 33. Torque converter oil pressure sensor
13. Radiator fan pump EPC valve 34. Transmission main flow valve operation pressure sensor
14. Radiator fan reverse valve 35. Start switch ACC terminal
15. Transmission main pressure variable valve 36. AISS LOW switch
16. Transmission main flow selector valve 37. Gear shift lever
17. Engine start relay 38. Machine lock-out switch (optional)
18. Battery relay 39. Machine lock-out operation lamp (optional)
19. Transmission controller self-holding relay 40. Steering pump lockout valve (optional)
20. Engine start self-holding relay 41. Steering and hoist pump lockout valve (optional)
21. Limp-home connector 42. Steering and hoist pump oil pressure sensor (optional)
22. Transmission controller
10-170 HD465-8, HD605-8

GEAR SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFT RANGE

The gear is moved automatically in each gear position as shown in the follow figure.
REMARK
* When F1 is selected on "F 1 Start at D Position Setting", minimum gear speed at D range is F1.
("F 1 Start at D Position Setting" can be changed on the User Menu in operator mode of Machine monitor.)
HD465-8, HD605-8 10-171

Automatic gear shift diagram

The upshift/downshift points, torque converter lockup ON/OFF points, and automatic brake ON/OFF points in each mode as
shown in the following figure.
Control in power mode

q The upshift point is set correctly in the range of 1725 to 2010 rpm corresponding to the throttle position, acceleration of the
machine, and gear speed.
q The downshift point is also set correctly in the range of 1175 to 1350 rpm corresponding to the throttle position and gear
speed.
10-172 HD465-8, HD605-8

Control in brake (foot brake) mode

q If the travel speed decreases to approximately 20 km/h or below in the 4th gear speed, approximately 15 km/h or below in
the 3rd gear speed, or approximately 11 km/h or below in the 2nd while the foot brake is used, the current gear speed (F4,
F3, or F2) is maintained.
q If the machine travels down a slope with the foot brake applied and the engine speed low and held in the current gear speed.
The cooling oil is not sufficient and the engine can get too hot.
q If the travel speed decreases to 5 km/h or below, or the foot brake is turned OFF, or the current gear speed is kept for a
long time, the current gear speed is canceled and a proper gear speed is selected corresponding to the travel speed.
Control in other modes

q The upshift point is set correctly in the range of 2010 to 2070 rpm corresponding to the gear speed, the shift condition, and
the accelerator.
q The downshift point is also set correctly in the range of 1150 to 1350 rpm corresponding to the gear speed, the shift con-
dition, and the accelerator.
Control in lock-up is turned ON

q The lock-up ON point is set correctly in the range of 1250 to 1500 rpm corresponding to the torque converter inlet speed
(engine speed) and output speed (transmission input speed), and the throttle position.
q Lockup "OFF" point is set to 1100 rpm in "F1"or "F2" and set to 1050 rpm in "F3" to "F7". The lock-up is not turned ON in "R".
q If the machine starts down a slope with the accelerator pedal released, the lock-up is not turned ON in F1 or F2 until the
accelerator pedal is depressed or the brake is applied.
Control in auto brake (overrun prevention)

q When the accelerator pedal is released, the auto brake "ON" point is set to 2300 rpm in "F1" to "F5" and set to 2400 rpm
in "F6" to "F7".
q When the accelerator pedal is depressed, the auto brake "ON" point is set to 2400 rpm in "F1" to "F4" and set to 2450 rpm
in "F5" to "F7".
q The auto brake "OFF" point is set to 2300 rpm.
SAFE TRAVEL FUNCTION OF TRANSMISSION CONTROL SYSTEM
q Neutral safety function
To prevent malfunction of the machine, the engine does not start while the gear shift lever is not in N. The supply voltage
cut off to prevent the starting motor drive output.
(Safety circuit to prevent the machine movement when the engine is started)
q Reverse travel safety function
The machine does not travel in reverse when the dump lever is in RAISE position and the dump body is seated. It also does
not travel in reverse when not in FLOAT position and the dump body is not against frame (function to prevent tip over).
q Gear speed limit function when dump body is lifted
While the dump body is not against frame after dump, upshift operation is limited. When the gear shift lever is in position D
to L, the machine starts in F1. The gear will not upshifted until the dump body is seated.
q Neutral coast prevention function
During travel at speed of 4 km/h or higher, if the gear shift lever is set in N (NEUTRAL), the gear will not go to neutral. At
this time, the centralized warning lamp flashes and the alarm buzzer sounds. Also, during downhill travel with the gear shift
lever in N (NEUTRAL) position, if the travel speed exceeds 17 km/h, the gear is shifted automatically to a gear speed suit-
able for the travel speed, and the centralized warning lamp flashes and the alarm buzzer sounds.
REMARK
Do not operate the gear shift lever to N (NEUTRAL) position while you travel on flat ground or downhill. Always set the gear
shift lever to any position of D to L before you start travel.
HD465-8, HD605-8 10-173

PROTECTION FUNCTION OF TRANSMISSION CONTROL SYSTEM

q Downshift limit function
Gear shift lever operated as follows during travel, from D to any position 6 to L. For example, when you travel in D (F7), if
the gear shift lever is operated to 4, the transmission does not shift directly from F7 to F4. It shifts down from F7 to F6, from
F6 to F5, then to F4 in sequence, corresponding to the travel speed.
(If a mistake is made in operation, the gear does not miss shift.) (Engine overrun prevention function)
q Directional selection limit function
While the machine travels in reverse at a speed of 4.0 km/h or higher, if the gear shift lever is set to position D or any one
6 to L, the gear is not immediately moved to the forward gear, but the gear is set to N and the engine speed is decreased
to lower the travel speed. When the travel speed is decreased below 4.0 km/h, the gear is moved to the forward gear.
(Prevention of overload on the power train and improvement of durability and reliability)
While the machine is traveling forward at a speed of 4.0 km/h or higher, even if the gear shift lever is set to position R, the
gear is not immediately shifted to the reverse gear, but the gear is set to N and the engine speed is decreased to decrease
the travel speed. When the travel speed is decreased below 4.0 km/h, the gear is shifted to the reverse gear.
If the machine has started with the gear shift lever in position N and is moving forward or in reverse at a speed of 4.0 km/h
or higher with the gear shift lever still in position N, the gear is not moved but kept in N even if the gear shift lever is set to
R. When the travel speed is decreased below 4.0 km/h, a start is permitted.
(Prevention of overload on the power train and improvement of durability and reliability)
q Power train overrun prevention retarder brake function
If the engine speed or transmission input shaft speed increases to 2400 rpm or higher, the centralized warning lamp illumi-
nates and the alarm buzzer operates. If the transmission input shaft speed increases to the auto brake (for overrun preven-
tion) "ON" point, the retarder brake operates automatically. (To prevent overrun of the engine, torque converter, and
transmission, and improve durability and reliability.)
SELF-DIAGNOSIS FUNCTION OF TRANSMISSION CONTROL SYSTEM
The controller performs the self-diagnosis on the system and shows sensed abnormality. The contents of the self-diagnosis
are shown on the monitor. If any abnormality sensed by the self-diagnosis, the information on it is transmitted to the network
and the monitor shows the action level. The transmission system caution lamp, other caution lamps, and alarm buzzer may
operate in this case.
10-174 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION GEAR SHIFT CONTROL SYSTEM
GEAR SHIFT CONTROL SYSTEM

AUTOMATIC GEAR SHIFT CONTROL OF GEAR SHIFT CONTROL SYSTEM
The transmission gear is moved up and down corresponding to the shift map kept in the memory of the controller.
There are 4 shift maps, which are used corresponding to the condition of each input signal.
The table shows the setting of each mode.
Mode Setting condition

Brake mode Brake signal "ON"
When these conditions are touched
Coast mode q Brake signal "OFF"
q Accelerator pedal released
Power mode q Brake signal "OFF"
q Accelerator pedal depressed
Partial delay q In a certain period of time after brake signal "OFF"
q Not accelerator pedal released and not full acceleration
Other mode Shift down with engine full throttle
Brake mode
Keeps engine speed high at downshift point and upshift point. To insure enough quantity of retarder cooling oil and increase
engine brake effects.
Coast mode
Increases the difference in engine speed between upshift point and downshift point to decrease not necessary gear shifts.
Power mode
This mode maximizes the machine power to get maximum production.
However, the acceleration variable shift point is adopted. It senses machine acceleration to upshift to improve acceleration
when the load on the machine is light. And at the same time, fuel consumption, noise, and shift shock are improved.
When the gear shift lever is in F1 position, the maximum output at the engine maximum speed is limited to reduce noise.
Partial delay
Decreases the number of gear shifts between mode changes.
Other mode
When the machine is down shifted with engine at full throttle. This increases the engine speed and secure enough operate
force, and then upshifts.
SHIFTING PROCEDURE IN EACH GEAR SHIFT LEVER POSITIONS OF GEAR SHIFT
CONTROL SYSTEM
When gear shift lever is in position D
q When upshift (in POWER mode)
1. When gear shift lever is put in D position, transmission is set to range of F2. (When F1 selected in setting, machine will start
in F1 at D Position, transmission is set to F1 torque converter range.)
2. When the accelerator pedal is depressed, the engine speed increases and the travel speed increases. When the transmis-
sion input speed gets to1250 to 1500 rpm, the lockup clutch engages and the torque converter is set in direct.
3. When the engine speed increases further to 1775 to 2010 rpm, the gear is upshifted to F3. (For F1 to F2, gear is upshifted
at 2010 rpm.)
The engine speed is decreased during the upshift procedure to reduce the gear shift shock.
4. The engine speed decreases just after the an upshift. But it increases again as the travel speed increases, and the gears
upshift to F4 - F7 similar to step 3 above.
HD465-8, HD605-8 10-175

GEAR SHIFT CONTROL SYSTEM 10 STRUCTURE AND FUNCTION
q When downshift (in POWER mode)

1. If the load increases and the engine speed decreases to 1175 to 1350 rpm, the gear will down shift one step (for example,
from F6 to F5).
The engine speed is increased during the down shift procedure to reduce the gear shift shock.
2. When the travel speed decreases further, the gear is shifted to F2 in sequence (to "F1" if F1 is selected in F 1 Start at D
Position Setting). The lockup clutch is disengaged and torque converter drive starts.
REMARK
The set engine speed and operation condition in this explanation may vary with different travel conditions. For details, see "Au-
tomatic gear shift diagram".
When gear shift lever is in “6”, “5”, “4”, “3”, “2”, or “L”
The automatic gear shift procedure in F1 to F6 (F5, F4, F3, F2) is similar to that "When gear shift lever is in position D" explained
above.
When gear shift lever is in position R

This gear shift lever position is for reverse travel.
The safety functions related to reverse travel are the forward-reverse inhibit and reverse safety functions. If the machine is not
operated correctly, gear shift is restricted.
When gear shift lever is in position N

When the gear shift lever is in neutral, the transmission does not operate any clutch.
DISABLED TIME OF GEAR SHIFT CONTROL SYSTEM
In the automatic shift range, shift time is controlled during the gear shift
procedure to prevent malfunction caused by a speed change caused by
the gear shift.
Shift time is controlled carefully in each gear shift pattern by the all-gear
step electronic modulation system.
The gear shift patterns and rough unauthorized shift time values are
shown below.
10-176 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION DIRECTION CONTROL SYSTEM
DIRECTION CONTROL SYSTEM

RIM PULL LIMIT FUNCTION FOR OVERLOAD PREVENTION OF DIRECTION CONTROL
SYSTEM
To prevent overload to the power train, the function to restrict the upper
limit of the rim pull in gear speed R is provided. The details are shown
in the figure below.
REMARK
The rim pull upper limit at input speed of 0 rpm is set in the range of 52
to 55%, dependent on the control condition of the hydraulic fan.
FUNCTION OF THROTTLE LIMIT FUNCTION AT F1 START AT D POSITION SETTING OF

DIRECTION CONTROL SYSTEM
While the machine travels after F1 is selected in F 1 Start at D Position Setting in the user menu. If the parking brake, foot
brake, or retarder brake is applied, the throttle will decrease automatically to prevent damage of the clutch.
HD465-8, HD605-8 10-177

KOMATSU TRACTION CONTROL SYSTEM (KTCS) 10 STRUCTURE AND FUNCTION
KOMATSU TRACTION CONTROL SYSTEM (KTCS)

KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM DIAGRAM
1. Acceleration sensor 4. Wheel speed sensor (RR)

2. Rudder angle sensor 5. Wheel speed sensor (RL)
3. Rear wheel brake (right) 6. Rear wheel brake (left)
FUNCTION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS)
When the machine travels on soft ground or up hill road, and too much torque is applied to the tires, the tires may turn and the
machine may not travel. In this case, the KTCS automatically applies the brake to the spinning tires to control the torque applied
to the other tires, thus the machine can travel.
REMARK
q Turn of each tire is sensed which compares the tire speed obtained from the wheel speed sensor with the travel speed
obtained from the acceleration sensor.
10-178 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION KOMATSU TRACTION CONTROL SYSTEM (KTCS)
OPERATION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM LOGIC
Not in operation
1. When no tires slip during normal travel, KTCS does not operate and the brake is not applied.
2. When the machine turns, the condition to start the control varies relative to the sensed rudder angle. Thus KTCS senses
the speed difference between the right and left wheels, and does not operate.
During operation
If any tire slip is sensed while the accelerator pedal is depressed, as shown in the graph, KTCS operates to apply the brake to
that tire. As a result, slip of the tire is reduced and the machine can travel.
HD465-8, HD605-8 10-179

TRAVEL SPEED LIMITATION SYSTEM 10 STRUCTURE AND FUNCTION
TRAVEL SPEED LIMITATION SYSTEM

(For machine with travel speed limitation system)
SYSTEM DIAGRAM OF TRAVEL SPEED LIMITATION SYSTEM
Input/output signal
a: Limiting speed signal j: Overload control ON/OFF signal
b: Maximum speed limit indicator lamp signal k: Transmission output shaft speed signal
c: Overspeed caution signal m: Empty/Load status signal
d: Overload caution signal n: Brake control ON/OFF signal
e: Engine throttle correction signal p: Dump body position voltage signal
f: Accelerator pedal signal q: Suspension pressure sensor error signal
g: Accelerator pedal sensor error signal r: Dump body position sensor error signal
h: Overload status signal
10-180 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION TRAVEL SPEED LIMITATION SYSTEM
1: Transmission controller 6: Accelerator pedal

2: Monitor controller 7: Inclination angle sensor
3: Engine controller 8: Suspension pressure sensor
4: KOMTRAX Plus controller 9: Transmission output speed sensor
5: Retarder and hoist controller
FUNCTION OF TRAVEL SPEED LIMITATION SYSTEM
Vehicle speed limit function
q The vehicle speed limit function automatically controls the travel speed, despite the road grade and the payload, to prevent
the speed from exceeding the limiting speed which is set by using the machine monitor.
q With the vehicle speed limit function, the transmission controller and the retarder and hoist controller calculate the travel
speed and machine acceleration from the signals sent by the transmission output shaft speed sensor. These two controllers
command the engine throttle and the retarder valve to control the travel speed.
REMARK
If the machine enters the downhill with the accelerator pedal fully depressed, it is possible to exceed the limiting speed
temporarily.
Overload speed limit function
q When the payload reaches overload, the overload speed limit function automatically controls the machine travel speed to
prevent machine components from being damaged.
q The KOMTRAX Plus controller calculates the payload from signals sent by the suspension pressure sensor etc. and judges
if the payload is an overload or not.
If it is an overload, the transmission controller and the retarder and hoist controller send signals to the engine throttle or the
retarder valve, and control the machine travel speed.
REMARK
q If the machine enters the downhill with the accelerator pedal fully depressed, it is possible to exceed the limiting speed
temporarily.
q The limiting speed is predetermined and it is impossible to change.
HD465-8, HD605-8 10-181

TRAVEL SPEED LIMITATION SYSTEM 10 STRUCTURE AND FUNCTION
OPERATION OF TRAVEL SPEED LIMITATION SYSTEM

Operation of the vehicle speed limit function
q As shown below, if the accelerator pedal is kept depressed, the vehicle speed limit system controls the machine travel
speed by controlling the engine throttle and the retarder valve.
q The overload speed limit function controls the machine speed in the same way as the vehicle speed limit function.
REMARK
For the setting of the vehicle speed limit function, see TEST AND ADJUST, "METHOD TO SET TRAVEL SPEED LIMIT".
ap: Accelerator pedal signal V: Travel speed

atm: The engine throttle position after controlling of the V (lmt): Limiting speed
transmission controller
t1: When the machine travel speed approaches the limiting speed, the transmission controller commands the engine to prevent
the travel speed from exceeding the limiting speed.
REMARK
The value of the output to the engine throttle is decided according to the limiting speed, the accelerator pedal signal, and
the travel speed and acceleration calculated from the transmission output shaft speed sensor signal.
10-182 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION TRAVEL SPEED LIMITATION SYSTEM
t2: At the downhill, the machine accelerates and sends the engine throttle signal to decelerate.
t3: At the downhill, the machine accelerates even when the engine throttle signal is minimum, and the retarder control starts
operating.
The reader control also starts under the condition below.
q The machine accelerates with the accelerator pedal released.
q The machine travel speed exceeds the predetermined speed.
REMARK
q The value of the retarder command is decided according to the limiting speed, the travel speed and acceleration cal-
culated from the transmission output shaft speed sensor signal.
q When the brake is being controlled, the engine throttle signal from the transmission controller is minimum.
q Once the retarder control is started, the control continues until the machine decelerates.
t4: When the machine enters the level road, the machine decelerates and the retarder control is canceled.
Operation of the overload speed limit function
q The KOMTRAX Plus controller is monitoring the payload when the machine is traveling after loading. And if the payload
reaches the overload, the controller judges the overload, and it outputs the overload caution signal and the alarm buzzer
sounds.
q Once the controller judges the overload, the judgment is kept until the payload is dumped.
REMARK
q The threshold of the overload is in conjunction with that of the outside red lamp indicator lighting, so it is possible to
adjust the threshold of the overload by setting the indication range of the outside indicator lamp in the service mode,
"Payload Meter Setting".
q For the changing of the indicator range of the outside indicator lamp, see TEST AND ADJUST, "PROCEDURE TO SET
BY PAYLOAD METER SETTING (SETTING OF RANGE OF EXTERNAL LAMPS)".
HD465-8, HD605-8 10-183

POWER TRAIN COMPONENTS 10 STRUCTURE AND FUNCTION
POWER TRAIN COMPONENTS

DRIVE SHAFT
STRUCTURE OF DRIVE SHAFT
General view
1: Front drive shaft 2: Rear drive shaft
10-184 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION POWER TRAIN COMPONENTS
FUNCTION OF DRIVE SHAFT
The power from the engine is transmitted to the output shaft, the front drive shaft (1), transmission, and then to the rear drive
shaft (2).
HD465-8, HD605-8 10-185

TORQUE CONVERTER AND PTO

PTO
Abbreviation for Power Take Off
STRUCTURE OF TORQUE CONVERTER AND PTO
A: Main relief oil pressure pickup port F: To lockup clutch

B: Torque converter oil inlet G: Torque converter oil outlet oil pressure pickup port
C: Torque converter oil inlet oil pressure pickup port H: To transmission lubrication
D: Torque converter oil outlet J: Main flow selector valve inlet oil pressure pickup port
E: To transmission control valve
1: PTO gear (number of teeth: 91) 5: Torque converter valve
2: Brake cooling, brake control pump install location 6: Torque converter intermediate oil pressure sensor
3: Steering and hoist pump install location 7: Torque converter outlet oil temperature sensor
4: Radiator fan, power train and brake cooling duplex pump 8: Oil pressure sensor for main flow selector valve
install location
REMARK
PTO gears on three positions are identical. Spline has fourteen teeth.
10-186 HD465-8, HD605-8

Section view
1: Coupling 10: Stator shaft

2: Input shaft (number of teeth: 108) 11: Sleeve
3: Case 12: Inner race
4: Drive case 13: Free wheel
5: Boss 14: Stator
6: Turbine 15: Lockup clutch disc
7: Outer race 16: Lockup clutch piston
8: Pump 17: Lockup clutch housing
9: Retainer 18: Retainer
HD465-8, HD605-8 10-187

SPECIFICATIONS OF TORQUE CONVERTER AND PTO

Type: 3-elements, 1-stage, 2-phase, with modulation mechanism and lockup clutch
Lockup clutch: Wet-type single-disc clutch with hydraulic control (modulation mechanism)
Stall torque ratio: 2.25
POWER TRANSMITTING ROUTING OF TORQUE CONVERTER
When lockup clutch is "disengaged"
Drive case (4) is disconnected from boss (7) and turbine (6) and the torque converter works as a normal torque converter.
Engine power
↓
Drive shaft
↓
Coupling (1)
↓
Input shaft (2), clutch housing (3), drive case (4) and pump (5) rotate to-
gether
↓
Oil is used as a medium
↓
Turbine (6) and boss (7)
↓
Transmission input shaft (8)
The power transmitted to input shaft (2) is used to operate the pump
through PTO gear.
When lockup clutch is "engaged"

Drive case (4) is connected to boss (7) and turbine (6), and torque converter is locked up.
Engine power
↓
Drive shaft
↓
Coupling (1)
↓
Input shaft (2), clutch housing (3), drive case (4) and pump (5) rotate to-
gether
↓
Lockup clutch (9)
↓
Boss (7)
↓
The power transmitted to input shaft (2) is used to operate the pump
through PTO gear.
10-188 HD465-8, HD605-8

TORQUE CONVERTER OIL FLOW

1. The oil pressure is regulated to a set pressure or below by the
torque converter relief valve through the primary relief valve. The oil
flows into port (A), goes through the oil hole in the stator shaft (1)
into pump (2).
2. The oil is given centrifugal force by pump (2) and flows into turbine
(3) to transfer its energy to turbine (3).
3. Oil from turbine (3) is sent to stator (4) and flows into pump (2)
again. However, part of the oil goes between turbine (3) and stator
(4) and is sent from port (B) to the oil cooler. It is then used to lubri-
cate the transmission.
HD465-8, HD605-8 10-189

LOCKUP CLUTCH ECMV

ECMV
Abbreviation for Electronic Control Modulation Valve
STRUCTURE OF LOCKUP CLUTCH ECMV
NOTICE
Do not disassemble. Adjustment is required to maintain the performance once disassembled.
A: To clutch P1: Clutch oil pressure pickup port

DR: Drain T: Drain
P: From pump
1: Proportion solenoid connector 4: Pressure control valve
2: Sleeve 5: Nameplate (*1)
3: Proportion solenoid
*1
Clutches
Marked on nameplate
engaged
Lockup K******
10-190 HD465-8, HD605-8

FUNCTION OF LOCKUP CLUTCH ECMV

q This valve is used to adjust the clutch oil pressure to the set pressure and select a clutch.
q Since clutch pressure apply qualities are used in the modulation waveform, the ECMV is capable of smooth clutch lockup.
Shock is reduced from gear shifts, and the generation of peak torque in the power train is prevented. As a result, it provides
a comfortable operation and increases the durability of the power train.
When torque converter mode changes to direct drive mode
When gear is moved (in direct travel)
OPERATION OF LOCKUP CLUTCH ECMV

Torque converter mode
While no current flows to the proportion solenoid (1), pressure control
valve (3) drains the oil from port (A) through drain port (T).
HD465-8, HD605-8 10-191

Direct drive mode (Torque converter changes to direct drive mode)

1. When current is supplied to proportion solenoid (1). Hydraulic force
balanced with the solenoid force, is applied to chamber (B) and
pushes pressure control valve (3) to the left. As a result, pump port
(P) and port (A) are opened and clutch oil fill is started.
2. As the clutch is filled with oil, the solenoid is balanced with the oil
pressure in the clutch port and the reaction force of pressure control
spring (2). Thus the pressure is adjusted.
10-192 HD465-8, HD605-8

TRANSMISSION
STRUCTURE OF TRANSMISSION
General view
A: Lubrication oil pick up port F: From oil cooler

B: To pump (suction) G: From torque converter (drain circuit)
C: To lockup H: lubrication oil relief valve
D: From torque converter (primary circuit) J: To breather
E: From torque converter (lubrication circuit)
HD465-8, HD605-8 10-193

1. Transmission input shaft 7. Transmission middle shaft speed sensor

2. Transmission control valve 8. Transmission output speed sensor
3. Transmission output shaft 9. Lubrication oil temperature sensor
4. Strainer 10. Main relief oil pressure sensor
5. Drain valve 11. Location of ground mount
6. Transmission input speed sensor
10-194 HD465-8, HD605-8

Section view A-A
HD465-8, HD605-8 10-195

1: Transmission input shaft 22: R ring gear (number of teeth: 93)

2: H sun gear (number of teeth: 34) 23: 2nd clutch
3: H ring gear (hub) 24: 2nd ring gear (number of teeth: 105)
4: H clutch 25: 2nd planetary pinion (number of teeth: 30)
5: H planetary pinion (number of teeth: 32) 26: 2nd sun gear (number of teeth: 45)
6: H carrier 27: 2nd, 1st carrier
7: L ring gear (hub) 28: 1st clutch
8: L clutch 29: 1st ring gear (number of teeth: 104)
9: H ring gear (number of teeth: 98) 30: 1st sun gear (number of teeth: 28)
10: L clutch housing 31: Transmission output shaft
11: 4th clutch housing 32: 1st planetary pinion (number of teeth: 38)
12: 4th clutch drum 33: 1st clutch piston
13: 4th clutch 34: 2nd clutch piston
14: 4th ring gear (hub) 35: Transmission middle shaft
15: 3rd planetary pinion (number of teeth: 21) 36: R clutch piston
16: 3rd clutch 37: R planetary pinion A (number of teeth: 21)
17: 3rd ring gear (number of teeth: 93) 38: 3rd clutch piston
18: 3rd sun gear (number of teeth: 51) 39: 3rd, R carrier
19: R clutch 40: 4th clutch piston
20: R planetary pinion (number of teeth: 21) 41: L clutch piston
21: R sun gear (number of teeth: 41) 42: H clutch piston
Structure of transmission
q The transmission consists of planetary gear mechanism and disc clutches with 7 forward speeds and 1 reverse.
q The transmission selects one rotation direction and one gear speed by set of 2 of the 7 disc clutches hydraulically by the
operation of the ECMV in the planetary gear mechanism.
q The transmission receives the power from the input shaft and transfers it to the output shaft. It changes its speed in the
forward 1st to 7th or reverse 1st by a mix of the H, L, and R clutches and the 4 speed clutches.
Number of plates and discs used
Clutch No. Number of plates Number of discs

H clutch 2 3
L clutch 4 5
4th clutch 3 4
3rd clutch 3 4
R clutch 5 5
2nd clutch 4 4
1st clutch 5 5
10-196 HD465-8, HD605-8

Mix of clutches for each speed range and reduction ratios
Gear speed Clutches engaged Reduction ratio

Forward 1st L x 1st 4.714
Forward 2nd L x 2nd 3.333
Forward 3rd H x 2nd 2.475
Forward 4th L x 3rd 1.825
Forward 5th H x 3rd 1.355
Forward 6th L x 4th 1.000
Forward 7th H x 4th 0.742
Reverse 1st LxR 3.969
DISC CLUTCH
STRUCTURE OF DISC CLUTCH
q It has piston (2), plate (3), disc (4), pin (5), spring (6), washer spring
(8), to fix ring gear (1).
q The internal teeth of disc (4) engages with the external teeth of ring
gear (1).
q Plate (3) is attached on clutch drum (7) by pin (5).
OPERATE DISC CLUTCH

Operation when clutch is ON (engaged)
1. The oil from the ECMV is routed to behind piston (2) through oil hole
of clutch drum (7) and pushes piston (2) to the left.
2. Piston (2) pushes plates (3) against discs (4) to hold rotation of
discs (4) with force between them.
3. As the internal teeth of discs (4) are engaged with the external teeth
of the gear (1), gear (1) is set.
HD465-8, HD605-8 10-197

Operation when clutch is OFF (disengaged)

1. When the oil from the ECMV is shut off, piston (2) is pushed back to
the right by spring (6).
2. The force between plates (3) and discs (4) is lost and gear (1) is
released.
REMARK
Washer spring (8) between pin part plate (3) and plate (3) is installed to
speed up the return of piston (2). This isolates plate (3) and disc (4) to
prevent rotation together when the clutch is disengaged.
10-198 HD465-8, HD605-8

POWER TRANSMITTING ROUTING OF TRANSMISSION

Forward 1st
L clutch (8) and 1st clutch (28) are set together hydraulically.
Power from torque converter
↓
↓
H carrier (6)
↓
L ring gear (7)
↓
L clutch (8)
↓
H ring gear (3)
↓
Transmission middle shaft (35)
↓
1st sun gear (30)
↓
1st planetary pinion (32)
↓
2nd, 1st carrier (27)
↓
Transmission output shaft (31)
HD465-8, HD605-8 10-199

Forward 2nd
L clutch (8) and 2nd clutch (23) are set together hydraulically.
↓
↓
H carrier (6)
↓
L ring gear (7)
↓
L clutch (8)
↓
H ring gear (3)
↓
L clutch housing (10)
↓
↓
2nd sun gear (26)
↓
2nd planetary pinion (25)
↓
↓
10-200 HD465-8, HD605-8

Forward 3rd
H clutch (4) and 2nd clutch (23) are set together hydraulically.
↓
↓
H carrier (6)
↓
H planetary pinion (5)
↓
H ring gear (3)
↓
↓
↓
2nd sun gear (26)
↓
↓
↓
HD465-8, HD605-8 10-201

Forward 4th
L clutch (8) and 3rd clutch (16) are set together hydraulically.
↓
↓
H carrier (6)
↓
L ring gear (7)
↓
L clutch (8)
↓
H ring gear (3)
↓
↓
↓
3rd sun gear (18) 2nd sun gear (26)
↓
3rd, R carrier (39)
↓
2nd ring gear (24)
↓
↓
↓
10-202 HD465-8, HD605-8

Forward 5th
H clutch (4) and 3rd clutch (16) are set together hydraulically.
↓
↓
H carrier (6)
↓
↓
H ring gear (3)
↓
↓
↓
3rd sun gear (18) 2nd sun gear (26)
↓
3rd, R carrier (39)
↓
2nd ring gear (24)
↓
↓
↓
HD465-8, HD605-8 10-203

Forward 6th
L clutch (8) and 4th clutch (12) are set together hydraulically.
↓
↓
H carrier (6)
↓
L ring gear (7)
↓
L clutch (8)
↓
H ring gear (3)
↓
↓
10-204 HD465-8, HD605-8


↓
4th clutch housing (11) 2nd sun gear (26)
↓
4th clutch piston (40)
↓
4th clutch (12)
↓
4th ring gear (14)
↓
3rd, R carrier (39)
↓
2nd ring gear (24)
↓
↓
↓
HD465-8, HD605-8 10-205

Forward 7th
H clutch (4) and 4th clutch (12) are set together hydraulically.
↓
↓
H carrier (6)
↓
↓
H ring gear (3)
↓
↓
10-206 HD465-8, HD605-8


↓
4th clutch housing (11) 2nd sun gear (26)
↓
4th clutch drum (12)
↓
4th clutch (13)
↓
4th ring gear (14)
↓
3rd, R carrier (39)
↓
2nd ring gear (24)
↓
↓
↓
HD465-8, HD605-8 10-207

Reverse 1st
L clutch (8) and R clutch (19) are set together hydraulically.

↓
↓
H carrier (6)
↓
L ring gear (7)
↓
L clutch (8)
↓
H ring gear (3)
↓
↓
↓
R sun gear (21) 2nd sun gear (26)
↓
R planetary pinion A (37)
↓
R planetary pinion B (20)
↓
10-208 HD465-8, HD605-8

3rd, R carrier (39)

(R ring gear set by R clutch = 3rd, R carrier (39) rotates in reverse
against transmission input shaft (1).)
↓
2nd ring gear (24)
↓
↓
↓
HD465-8, HD605-8 10-209

TRANSMISSION CONTROL VALVE

STRUCTURE OF TRANSMISSION CONTROL VALVE
General view
A: H clutch oil pressure pickup port G: 2nd clutch oil pressure pickup port
B: Lockup clutch oil pressure pickup port H: 1st clutch oil pressure pickup port
C: L clutch oil pressure pickup port J: To breather
D: 4th clutch oil pressure pickup port K: To torque converter valve
E: 3rd clutch oil pressure pickup port (To pilot circuits of main relief oil pressure select valve and
F: R clutch oil pressure pickup port main flow selector valve)
1: H clutch ECMV 6: R clutch ECMV
2: LOCKUP CLUTCH ECMV 7: 2nd clutch ECMV
3: L clutch ECMV 8: 1st clutch ECMV
4: 4th clutch ECMV 9: Last chance filter
5: 3rd clutch ECMV 10: Valve seat
10-210 HD465-8, HD605-8

FUNCTION OF TRANSMISSION CONTROL VALVE

q The lockup clutch ECMV operates when the machine travels forward at speed above the travel speed set by the transmis-
sion controller.
Table of ECMV operation
ECMV
L H 1st 2nd 3rd 4th R L/U
F1 ○ ○ ○
F2 ○ ○ ○
F3 ○ ○ ○
F4 ○ ○ ○
Gear
F5 ○ ○ ○
speed
F6 ○ ○ ○
F7 ○ ○ ○
N
R1 ○ ○
L/U: Indicates Lockup clutch ECMV.
HD465-8, HD605-8 10-211

FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV
ECMV
Abbreviation for Electronic Control Modulation Valve
STRUCTURE OF FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED
CLUTCH ECMV
NOTICE
Do not disassemble. Adjustment is required to maintain performance when disassembled.
General view, section view (for H, L, 4th, 3rd, R, 2nd, and 1st clutches)
A: To clutch Dr: Drain

P: From pump P1: Clutch oil pressure pickup port
T: Drain
1: Fill switch connector 5: Proportion solenoid
2: Proportion solenoid connector 6: Pressure control valve(*1)
3: Flow detection valve
7: Nameplate(*2)
4: Fill switch
*1: Pressure control valve spools H, 3rd, R, 2nd clutches, are different from 1st, L and 4th clutches.
*2: The nameplates are different for H, 3rd, R, 2nd, and 1st, L and 4th clutches.
Clutches engaged Marked on nameplate

H, 3rd, R, 2nd, 1st D******
10-212 HD465-8, HD605-8

Clutches engaged Marked on nameplate

L, 4th Q******
Structure
ECMV has the 2 components of the pressure control valve and the fill switch.
FUNCTION OF FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH
ECMV
q Pressure control valve
The proportion solenoid receives a current sent from the transmission controller and this valve converts it into oil pressure.
q Fill switch
This switch senses that the clutch is filled with oil, and has these functions.
1. Outputs a signal (a fill signal) to the controller when the clutch is
filled with oil.
2. Continues the signals (fill signals) to the controller to notify that the
oil pressure is applied to the clutch.
Range A: Prior to gear shift (oil is drained)
Range B: Clutch being filled
Range C: Pressure being adjusted
Range D: Clutch being filled (trigger period)
Point E: Fill is started
Point F: Fill is completed
REMARK
The control logic is made so that it does not recognize fill completion
when the fill switch is turned ON during the trigger period (Range D).
ECMV and proportion solenoid

For each ECMV, 1 proportion solenoid is installed.
It generates push as shown in the figure corresponding to the command current from the controller.
The push generated by the proportion solenoid is applied to the pressure control valve to generate hydraulic pressure as shown
below. Thus, the oil flow and pressure is controlled by the control of command current to change the push and let the pressure
control valve operate.
HD465-8, HD605-8 10-213

Current - push properties of proportion solenoid
Push - oil pressure properties of proportion solenoid
ECMV and fill switch

For each ECMV, 1 fill switch is installed.
When the clutch is filled with oil, the fill switch is turned ON by the pressure on the clutch. This signal allows the oil pressure to
raise.
OPERATION OF FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH
ECMV
ECMV command current sent from the controller controls the proportion
solenoid and the fill switch output signal.
The relation between the proportion solenoid command current for EC-
MV, clutch input pressure, and fill switch output signal is shown below.
Range A: Prior to gear shift (oil is drained)
Range B: Clutch being filled
Range C: Pressure being adjusted
Range D: Clutch being filled (trigger period)
Point E: Fill is started
Point F: Fill is completed
REMARK
The control logic is made so that it does not recognize fill completion
when the fill switch is turned ON during the trigger period (Range D).
10-214 HD465-8, HD605-8

Operation before gear shift (when oil is drained)

1. When no current flows to the proportion solenoid (1), pressure
control valve (3) drains the oil from clutch port (A) through drain port
(T).
2. Fill switch (5) is turned OFF at this time since no oil pressure is
applied to pressure valve (4).
Operation as it fills
When the current flows in proportion solenoid (1) with no oil in the
clutch, the oil pressure force equal to the solenoid force acts on cham-
ber (B) and pushes pressure control valve (3) to the left. As a result, oil
from pump port (P) starts to fill the clutch chamber through orifice (a) of
flow sense valve (4). At this time, a differential pressure is generated in
upstream and downstream of orifice (a) of flow detection valve (4). This
differential pressure pushes valve (4) to the left.
When the clutch chamber is filled with oil and flow from port (P) into
clutch port (A) stops, the differential pressure before and after orifice (a)
of flow detection valve (4) disappears. The oil pressure pushes flow de-
tection valve (4) to the right and turns "ON" fill switch (5).
HD465-8, HD605-8 10-215

Operation when pressure adjusts

When the current flows in proportion solenoid (1), the solenoid gener-
ates push in proportion to the current. This push of the solenoid is bal-
anced with the sum of the push generated by the oil pressure in clutch
port. The reaction force of pressure control spring (2), thus the pressure
is regulated.
10-216 HD465-8, HD605-8

MAIN RELIEF VALVE

FUNCTION OF MAIN RELIEF VALVE
q Main relief valve has the main relief pressure select function.
q In high gears (F3 to F7) requires a lower clutch pressure, the main relief pressure is set lower to decrease pump load, and
improves the fuel consumption.
OPERATE MAIN RELIEF VALVE
Operation when solenoid is "not active" (R, N, F1, and F2)
q While no current flows to proportion solenoid (1), chamber (A) is
connected with drain, and oil pressure does not rise.
q Main relief valve (3) adjusts the pressure as the hydraulic force of
chamber (B) and the force of spring (4) are balanced.
HD465-8, HD605-8 10-217

Operation when solenoid is "energized" (F3, F4, F5, F6, and F7)
q When the current flows in proportion solenoid (1), oil pressure which
balances with solenoid push is generated in chamber (A), piston (2)
is pushed to the left, and the main relief valve (3) is pushed.
q Since the sum of the hydraulic force in chamber (A) and chamber
(B) and the force of spring (4) are regulated, main relief pressure is
regulated at lower oil pressure in proportion to the push of the pro-
portion solenoid (1).
MAIN FLOW SELECTOR VALVE

FUNCTION OF MAIN FLOW SELECTOR VALVE
q The main flow valve is used to select the flow to the main relief valve.
q When the main pressure is maintained by only one of the two pumps, the oil from the other pump flows to the torque con-
verter, and not through the main relief valve. With this system, the pump load is reduced and also improves fuel efficiency.
OPERATION OF MAIN FLOW SELECTOR VALVE
This valve operates automatically corresponding to the engine speed set for each gear speed.
Operation condition
Engine speed (rpm)

Gear speed
ON→OFF OFF→ON
F1 1,000 1,100
F2 950 1,100
N 1,450 1,550
Operates normal in F3 to F7.

No operation in R.
10-218 HD465-8, HD605-8

Operation when solenoid is not active (pump flows are combined)

While no current flows in to proportion solenoid (1), no hydraulic force
is applied to chamber (A). The main flow selector valve (2) is pushed to
the left by spring (3). At this time, all the oil released by pumps (B) and
(C) flows from chamber (N) through the main relief valve (4) to the
torque converter.
HD465-8, HD605-8 10-219

Operation when solenoid is energized (pump flows are divided)

When the current flows in to proportion solenoid (1), hydraulic force is
applied to chamber (A) and the main flow selector valve (2) is pushed
to the right. At this time, only oil pressure from pump (B) goes through
main relief valve (4). The oil from pump (C) bypasses the main relief
valve (4) and flows to the torque converter.
10-220 HD465-8, HD605-8

AXLE
STRUCTURE OF FRONT AXLE
General view
1: Wheel hub
HD465-8, HD605-8 10-221

STRUCTURE OF REAR AXLE
1: Differential 3: Brake
2: Axle housing 4: Final drive
10-222 HD465-8, HD605-8

DIFFERENTIAL
STRUCTURE OF DIFFERENTIAL
Section view
1: Coupling 4: Side gear (number of teeth: 24)

2: Cross shaft 5: Pinion gear (number of teeth: 17)
3: Bevel gear (number of teeth: 46) 6: Bevel pinion (number of teeth: 13)
HD465-8, HD605-8 10-223

OPERATION OF DIFFERENTIAL
1. The power from the engine is transmitted to each axle through the
output shaft, front drive shaft, torque converter and transmission.
2. In the axle, the power is transmitted through the bevel pinion (5) to
bevel gear (1) changes directions and reduced in speed. Then
transmits to the axle shaft through pinion (6) and side gear (3).
3. The power transmitted to the axle shaft is further reduced in speed
by the planetary gear final drives, and then transmitted to the
wheels.
Operation when machine travels straight

While the machine travels straight, the right and left wheels rotate at the
same speed. The pinions (6) in the differential assembly does not ro-
tate. The power of differential case (2) is transmitted through pinions (6)
and side gears (3) to the right and left axle shafts evenly.
Operation when machine turns

When the machine turns, the right and left wheels rotate at different
speeds. The pinions (6) and side gears (3) in the differential rotate and
transmit the power of differential case (2) to the right and left axle shafts,
dependent on the difference in rotation speed between the right and left
wheels.
10-224 HD465-8, HD605-8

FINAL DRIVE
STRUCTURE OF FINAL DRIVE
General view
1: Sun gear (number of teeth: 19) 5: Inner hub

2: Planetary gear (number of teeth: 24) 6: Wheel hub
3: Planetary gear shaft 7: Drive shaft
4: Ring gear (number of teeth: 71) 8: Planetary carrier
FUNCTION OF FINAL DRIVE

The final drive decreases the speed but obtains a larger drive force by using a planetary gear mechanism and transmits drive
force to the tires.
OPERATION OF FINAL DRIVE

1. The power transmitted from the differential to sun gear (1) through drive shaft (7) is transmitted to planetary gear (2).
2. As the planetary gear turn in ring gear (4) which is attached, reduced rotation is transmitted to planetary carrier (8). Then
transmitted to the wheel attached to the planetary carrier (8).
HD465-8, HD605-8 10-225

WORK EQUIPMENT CONTROL 10 STRUCTURE AND FUNCTION
WORK EQUIPMENT SYSTEM

WORK EQUIPMENT CONTROL
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM
1: Retarder and hoist controller 5: Hoist valve

2: Hoist cylinder (right) 6: Hoist EPC valve
3: Dump body position sensor 7: Dump lever
4: Hoist cylinder (left)
FUNCTION OF WORK EQUIPMENT CONTROL

q When body position sensor (3) is at the set position with dump body raised, the control automatically moves dump lever (7)
to HOLD position and stops the dump body.
q The signal from dump lever (7) controlled by retarder and hoist controller (1) and operates hoist EPC valve (6). The pilot
pressure generated in hoist EPC valve (6) moves the spool valve (5) to control the hoist cylinder (2) and (4).
10-226 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION HOIST CONTROL
HOIST CONTROL
HOIST CONTROL SYSTEM DIAGRAM
1: Dump 8: Retarder and hoist controller

2: Dump body position sensor 9: Hydraulic pump
3: Dump lever (with potentiometer) 10: Hoist EPC valve
4: Electrical detent 11: EPC valve (electromagnetic proportion valve)
5: Engine speed (network information) 12: Hoist selection valve
6: Transmission controller 13: Hoist valve
7: Dump body speed control, float caution (network informa-
tion)
FUNCTION OF HOIST CONTROL

Hoist control function
The EPC valve (proportion solenoid valve), hoist selection valve, and steering pump selection are controlled to operate the
dump body. They correspond with the operation of the dump lever while the engine operates.
Lever position function

There are 4 positions in the dump lever operation, RAISE, HOLD, FLOAT, and LOWER.
When the dump lever is set to RAISE position, the dump body is lifted. When the dump body top rises to the set position of the
body position sensor, the lever is set to HOLD position.
REMARK
q The lever has the dump lever potentiometer and kick-out solenoid.
q The dump lever potentiometer signals to the retarder and hoist controller corresponding to the lever position.
q The lever kick-out solenoid holds the lever in RAISE position with an ON signal from the controller, and sends it to HOLD
position when receives OFF signal.
HD465-8, HD605-8 10-227

HOIST CONTROL 10 STRUCTURE AND FUNCTION
Dump body speed control function

When the dump body is lowered, just before the seated position, the open area of the EPC valve is reduced to control the speed
of the dump body and reduce the seat shock.
Dump body hold function with start switch at ON, OFF, and START
q When key is turned to ON position:
The HOLD signal is always output, regardless of the lever position. If the dump lever is operated with the engine stopped,
the HOLD condition does not change.
q When key is turned to OFF position:
The hoist valve is kept closed and the dump body is held, regardless of the lever position.
q When engine is started:
Immediately after the engine is started, the HOLD signal is output, regardless of the lever position.
Once the lever is set to HOLD position, normal operation can resume.
Float caution function

The float caution lamp on the machine monitor illuminates when FLOAT signal is not sent or dump body is not against the
frame.
FLOAT signal is sent and dump body is against the frame → Float caution is OFF.
LOAT signal is not sent or dump body is not against the frame → Float caution is ON.
Reverse limit function

Information on permission and prohibition of reverse travel is calculated.
[Lever is not in RAISE position and dump body is against the frame] or [Lever is in FLOAT position and dump body is not against
the frame] → Reverse travel is permitted.
[Lever is in RAISE position and dump body is seated] or [Lever is not in FLOAT position and dump body is not against the
frame] → Reverse travel is not permitted.
Calibration function
To absorb the individual difference of the body potentiometers, calibrate the dump body seat condition and dump body cylinder
condition.
REMARK
q After the dump body potentiometer is installed and adjusted or the retarder and hoist controller is replaced, perform cali-
bration corresponding these procedures.
Dump control calibration procedure
1. Dump control calibration procedure
Increase the hydraulic oil temperature to 80 to 90 °C.
2. Lower the dump body completely and start the engine. Change the lever from HOLD to FLOAT and make sure that the float
caution lamp goes out.
3. Raise the dump body and keep the lever at RAISE position until the cylinder stop. Raise the lever for minimum 5 seconds
at the cylinder stop position.
4. Lower the dump body completely and keep the lever in FLOAT for a minimum 5 seconds.
5. Run the engine at low idle and perform raise → FLOAT to raise the dump body to the maximum height, then lower the dump
body completely. Repeat this operation 10 times.
6. Run the engine at low idle and perform RAISE → FLOAT to raise the dump body to the maximum height, then lower the
dump body completely. Repeat this operation 10 times.
10-228 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION WORK EQUIPMENT SYSTEM COMPONENTS
WORK EQUIPMENT SYSTEM COMPONENTS

DUMP LEVER
STRUCTURE OF DUMP LEVER
HD465-8, HD605-8 10-229

WORK EQUIPMENT SYSTEM COMPONENTS 10 STRUCTURE AND FUNCTION
1: Lever
2: Rod
3: Spring
4: Spring
5: Retainer
6: Dump
7: Dump
8: Bushing
9: Solenoid
10: Nut
11: Rod
12: Detent spring
13: Retainer
14: Ball
15: Seat
16: Potentiometer
17: Lever
18: Rod
19: Rod
20: Detent spring
10-230 HD465-8, HD605-8

FUNCTION OF DUMP LEVER

q When lever (1) is operated, rod (18) moves up and down corre-
sponding to the operation distance of the lever, and turns the
shaft of potentiometer (16).
q The operation angle (travel) of the control lever is sensed by the
potentiometer (16) and is output in the form of a signal voltage to
the controller.
q One potentiometer (16) is installed and outputs 2 signal voltages
which are opposite to each other as shown in the "Output voltage
properties".
OPERATION OF DUMP LEVER

When dump lever is operated to FLOAT position
1. If the rod (2) on LOWER side is pushed down with lever (1), ball
(14) touches (a) of rod (11) in the middle of the travel (before
mechanical detent operation starts).
2. If rods (2) and (11) are pushed in, ball (14) pushes up retainer
(13) held by detent spring (12) and releases out to go over
projection (a) of rod (11).
3. Rod (18) on the opposite side, pushed up by spring (4) and ball
(14) is moved toward the small diameter side of projection (b) of
rod (19) by retainer (13) held by detent spring (20).
4. If the lever is released, rod (18) is held by (b) of rod (19) and the
ball press force, thus the lever is maintained in the FLOAT posi-
tion.
HD465-8, HD605-8 10-231

When the dump lever is released from FLOAT position

When you return lever (1) from FLOAT position, push it down with
force larger than the hold force of rod (19), detent spring (20), retain-
er (13), and ball (14).
When the dump lever is operated to LOWER position

1. If the lever (1) is pushed further passed FLOAT position, it is set
in LOWER position.
2. Rod (18) is pushed up by spring (4) corresponding to the opera-
tion distance of lever (1).
3. Since lever (17) installed to the turn shaft with which potentiom-
eter (16) senses the displacement is connected to rod (19),
potentiometer (16) output voltage corresponding to the vertical
travel of the rod.
10-232 HD465-8, HD605-8

When the dump lever is operated to RAISE position

1. If the rod (18) on RAISE side is pushed down with lever (1), ball
(14) touches projection (a) of rod (19) in the middle of the travel
(before electrical detent operation starts).
2. If rods (18) and (19) are pushed further, ball (14) pushes up
retainer (20) held by detent spring (13) and releases out to go
over projection (a) of rod (19).
3. At this time, rod (2) on the opposite side pushed up by spring (4).
4. If the rod (9) is pushed up while current flows in solenoid (2), nut
(10) attracted by bushing (8).
5. As a result, rod (2) is kept pushed up. If the operator releases the
lever, the lever is held in RAISE position.
When the dump lever is released from RAISE position

To return lever (1) from RAISE position, push it down with a force. It
also goes back to the HOLD position when the solenoid current is
turned OFF.
HD465-8, HD605-8 10-233

HOIST EPC VALVE

EPC
Abbreviation for Electromagnetic Proportion Control
STRUCTURE OF HOIST EPC VALVE
General view
A: To hoist valve (RAISE side) P1: From radiator fan pump

B: To hoist valve (LOWER side) P2: To automatic suspension (OPT), pressure pickup port
C: To cooling fan motor R1: Sequence valve
F: To steering and hoist control pump, hoist control, and ra- R2: Pressure reducing valve
diator fan pump T: To hydraulic tank
1: Solenoid assembly (solenoid a) 2: Solenoid assembly (solenoid b)
FUNCTION OF HOIST EPC VALVE
The dump EPC valve is controlled by the retarder and hoist controller. It sends the oil from the hydraulic pump to the hoist valve
to select and control the pilot pressure and control the hoist valve.
10-234 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION STEERING SYSTEM DIAGRAM
STEERING SYSTEM
STEERING SYSTEM DIAGRAM
1: Steering cylinder (right) 6: Steering cylinder (left)

2: Steering column 7: Secondary steering motor
3: Demand valve 8: Secondary S/T oil pressure sensor
4: Steering oil pressure sensor 9: Secondary steering pump
5: Orbitrol valve
HD465-8, HD605-8 10-235

STEERING SYSTEM FUNCTION 10 STRUCTURE AND FUNCTION
STEERING SYSTEM FUNCTION

Automatic secondary steering function
If the engine stops or the hydraulic pump fails, the oil flow in the steering circuit decreases below the specified value while the
machine operates. The secondary steering pump is operated automatically to secure oil pressure for steering.
This system also operates manually.
Self-check function
q After the key is turned to "ON" position and the controller starts, the automatic steering system operates to perform the
self-check automatically. This makes sure the secondary steering system has no trouble before the machine is operated.
q The self-check result from the system calculated by the input value of the steering pressure sensor. If the oil pressure is
equal to or above the set value when the self-check is performed, the system is normal. If the former is below the set value,
the systems abnormal.
q The self-check is completed in 3 seconds, regardless of the measured result of the system.
REMARK
If the self-check result is abnormal, it triggers the action level, warning symbol, and buzzer.
Once the system is normal, the self-check is not performed again until the engine is started and stopped.
For the self-check, two systems of emergency steering operate, one and then the other.
10-236 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION STEERING COLUMN
STEERING COLUMN
STRUCTURE OF STEERING COLUMN
1. Steering shaft 4. Yoke

2. Steering column 5. Joint shaft
3. Lock lever 6. Orbitrol valve
HD465-8, HD605-8 10-237

STEERING LINKAGE 10 STRUCTURE AND FUNCTION
STEERING LINKAGE
STRUCTURE OF STEERING LINKAGE
1. Center lever 3. Arm (A-frame)

2. Tie rod 4. Knuckle arm
10-238 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION STEERING SYSTEM COMPONENTS
STEERING SYSTEM COMPONENTS

DEMAND VALVE
STRUCTURE OF DEMAND VALVE
General view
LS: LS port PH: To hoist valve

P1: From steering and hoist pump PST: To orbitrol valve
P2: From steering and hoist pump PT: Drain port
PE: From secondary steering pump
HD465-8, HD605-8 10-239

STEERING SYSTEM COMPONENTS 10 STRUCTURE AND FUNCTION
Section view
1: Spool 4: Relief valve

2: Check valve 5: Spool return spring
3: Plug 6: Check valve spring
10-240 HD465-8, HD605-8

FUNCTION OF DEMAND VALVE

q Demand valve divides the oil sent from the steering pump and the hoist pump for the work equipment. Then sends it to the
steering and hoist circuit corresponding to the pressure signal from the orbitrol valve.
q Demand valve is a load sense type and controls spool (1) by the operation of steering.
q When steering not being operated (when no oil is necessary in the steering circuit), the demand valve sends all the oil from
the pumps to the hoist valve.
q When the steering is operated, the quantity of oil necessary for steering is sent to the orbitrol valve, and the remaining is
sent to the hoist valve.
q In this procedure, the hydraulic power loss in the steering circuit is reduced.
HD465-8, HD605-8 10-241

OPERATION OF DEMAND VALVE
When orbitrol valve is at neutral

q The pressurized oil from the steering pump and the hoist pump goes into port (A) and (B).
q When the orbitrol valve is at neutral, port (LS) is connected to tank port (R) and LS pressure is the same with the tank pres-
sure. And the pressure of port (P) rises.
q The pressurized oil from port (A) through orifice (a), goes into the chamber (C), and moves spool (1) to the right.
q Port (LS) and chamber (D) are connected to the tank, and the force moves spool (1) to the left. This is only the force of
spool return spring (5).
q The pressure in chamber (C) rises until it is over the set pressure of spool return spring (5).
q Spool (1) stops in the position shown in figure, and all the pressurized oil from the steering pump and hoist pump flows to
the hoist valve.
10-242 HD465-8, HD605-8

When orbitrol valve is operated

q When the steering is operated, port (P) and port (LS) are connected, and the circuit between the tank port (R) and port (LS)
is shut off.
q The hydraulic pressure of port (P) of the orbitrol valve acts on chamber (C) of spool (1).
q The hydraulic pressure of port (LS) of the orbitrol valve acts on chamber (D).
q There is a difference in the area of the opening of orifice (b) when the steering is turned quickly and when it is turned slowly.
q The hydraulic pressure on the two sides of the orifice (b) changes and a pressure difference is caused.
q Spool (1) moves to balance the oil in chamber (C) pushes to the right, and the force of the oil in chamber (D) pushes to left
+ return spring (5).
q The larger the difference in pressure at port (P) of orbitrol valve is, the more spool (1) moves to the right.
HD465-8, HD605-8 10-243

When steering wheel is operated quickly
1. The area of opening of orifice (b) is large.

2. Spool (1) moves more to the right corresponding to the position where differential pressure of the two sides of orifice (b)
and spool return spring (5) are balanced.
3. The pressurized oil flows to operation of steering wheel (7).
10-244 HD465-8, HD605-8

When steering wheel is operated slowly
1. The area of opening of orifice (b) is small.

2. Spool (1) moves a little to the right corresponding to the position where differential pressure of the two sides of orifice (b)
and spool return spring (5) are balanced.
3. The pressurized oil flows to operation of steering wheel (7).
HD465-8, HD605-8 10-245

STEERING RELIEF VALVE

STRUCTURE OF STEERING RELIEF VALVE
1: Main valve
2: Valve seat
3: Pilot poppet
4: Spring
5: Adjustment screw
FUNCTION OF STEERING RELIEF VALVE
q This valve is located in the demand valve and releases oil from
the pump to prevent pump damage when the steering cylinder
travel ends, or unusual pressure occurs. (This valve sets the
maximum pressure of the circuit.)
OPERATION OF STEERING RELIEF VALVE

q Port (A) is connected to the pump circuit, and port (C) is connect-
ed to the tank drain circuit.
q Oil flows through the orifice of the main valve (1), and port (B) is
filled with oil.
q Also, the pilot poppet (3) is set in the valve seat (2).
q When the pressures in port (A) and port (B) balance with the pop-
pet spring force (set pressure), the pilot poppet (3) will open. Oil
in port (B) will release through port (D) to port (C), and the pres-
sure in port (B) will lower.
q When the pressure in port (B) lowers, the orifice in the main valve
(1) generates differential pressure between ports (A) and (B).
The pressure in port (A) pushes the main valve (1) to release oil
from port (A).
10-246 HD465-8, HD605-8

ORBITROL VALVE
STRUCTURE OF ORBITROL VALVE
P: From steering pump R: To steering cylinder

L: To steering cylinder T: To hydraulic tank
1: Cener pin 6: End cap
2: Spool 7: Gerotor
3: Sleeve 8: Ground
4: Drive shaft 9: Valve body
5: Spacer 10: Centering spring
HD465-8, HD605-8 10-247

Overview
The orbitrol valve is connected directly to the shaft of the steering col-
umn. It sends oil from the steering pump to the right or left steering
cylinder to change the travel direction of the machine.
Structure
q Top (A) of spool (9) is connected to the shaft of the steering col-
umn and further connected to sleeve (8) by center pin (7) (which
does not touch spool (9) when the steering wheel is in "neutral"
position) and center spring (3).
q Drive shaft (4) is engaged at top (B) with the center pin (7) and
forms one unit with sleeve (8). Its bottom is engaged with the
spline of rotor (6a) of gerotor (6).
q Valve body (5) has 4 ports, which are connected to the pump cir-
cuit, tank circuit, L.H. steering circuit, and R.H. steering circuit.
10-248 HD465-8, HD605-8

OPERATION OF ORBITROL VALVE

1. At neutral
q The oil from the pump goes through the demand valve and goes into port (P) of the orbitrol valve.
q Valve spool (2) is at the neutral position, so port (P) and the port (R and L) to cylinder are closed. No oil flows to the cylinder,
so the cylinder does not move.
q At the same times, port (LS) is connected through port (T) to the tank. As a result, the pressure which is lower than that of
port (P) is applied to port (LS). The steering control spool operates by oil pressures of port (P) side and port (LS) side. All
the oil from the pump flows to the hoist valve.
HD465-8, HD605-8 10-249

2. Steering to right
q When the steering wheel is turned (clockwise), input shaft (1) turns and valve spool (2) turns clockwise.
q The oil from the demand valve flows from port (P) to the gerotor below the valve.
q The quantity of oil flows to steering cylinder is measured. It goes into the valve spool (2) through holes in the valve sleeve
and port (R), and flows to the steering cylinder.
q In this procedure, the two cylinders are operated and the wheels turn to the right.
q The oil from the steering cylinder flows from port (L) through port (T) and goes back to the tank.
q At the same time, the oil pressure at port (P) is restricted by valve spool (2). A lower oil pressure than the pressure at port
(P) is applied to port (LS). (pressure differential differs corresponding to the area of the opening in the spool).
q The demand valve spool is operated by the difference in pressure between pressure at port (P) and the oil pressure at the
port (LS). As a result, only the necessary quantity of oil flows to the steering circuit, and remaining oil flows to the hoist valve.
10-250 HD465-8, HD605-8

3. Steering to left
q When the steering wheel is turned (counterclockwise), input shaft (1) turns. When this happens, valve spool (2) turns coun-
terclockwise.
q The oil from the demand valve flows from port (P) to the gerotor under the valve.
q After the amount of oil flowing to steering cylinder is measured, it enters the inside of valve spool, passes through hole in
the valve sleeve and port (L), and flows to the steering cylinder.
q In this way, the two cylinders are actuated and the wheels turn to the left.
q The oil returning from the steering cylinder flows from port (R) through port (T) and goes back to the tank.
q At the same time, the oil pressure at port (P) is restricted by valve spool (2), so a lower oil pressure than the pressure at
port (P) is applied to port (LS).
q The demand valve spool is operated by the difference in pressure between pressure at port (P) and the oil pressure at the
port (LS). As a result, only the necessary quantity of oil flows to the steering circuit, and remaining oil flows to the hoist valve.
HD465-8, HD605-8 10-251

Role of centering spring

1. Centering spring (3) consists of 6 X type springs layered together
and is incorporated between spool (2) and sleeve (1) as shown
in the figure.
2. When the steering wheel is turned, spool (2) shortens centering
spring (3), and angular displacement (a) of spool (2) and sleeve
(1) occurs.
3. As a result, ports of spool (2) and sleeve (1) are communicated
to send oil to the steering cylinder. However, when the rotation of
the steering wheel is stopped, the rotation of the gerotor also
stops, so oil is not sent to the steering cylinder and the oil pres-
sure rises.
4. To prevent this, when the rotation of the steering wheel is
stopped, spool (2) and sleeve (1) are rotated according to
angular displacement (a) by repulsive force of centering spring
(3) to return the steering wheel to the neutral state.
10-252 HD465-8, HD605-8

STEERING PUMP SELECTOR SOLENOID VALVE

STRUCTURE OF STEERING PUMP SELECTOR SOLENOID VALVE
General view
A: From orbitrol valve P: To steering and hoist pump

B: From demand valve T: To hydraulic tank
1: Solenoid assembly
FUNCTION OF STEERING PUMP SELECTOR SOLENOID VALVE

q This valve is controlled by the retarder and hoist controller. It sends the oil from the hydraulic pump to the steering and hoist
pump to change LS pressure and control the steering and hoist pump.
HD465-8, HD605-8 10-253

CROSS-OVER RELIEF VALVE

STRUCTURE OF CROSS-OVER RELIEF VALVE
SC1: To steering cylinder SC4: To steering cylinder

SC2: To steering cylinder SV1: To orbitrol valve
SC3: To steering cylinder SV2: To orbitrol valve
1: Valve body 5: Sleeve
2: Valve seat 6: Adjustment screw
3: Relief valve 7: Lock nut
4: Valve spring
10-254 HD465-8, HD605-8

SECONDARY STEERING PUMP

STRUCTURE OF SECONDARY STEERING PUMP
General view
A: From hydraulic tank B: To demand valve

SPECIFICATIONS OF SECONDARY STEERING PUMP
Type: Gear pump
Theoretical released volume: 14.4 cc/rev
Rated pressure: 20.6 MPa {210 kg/cm2}
FUNCTION OF SECONDARY STEERING PUMP
q The secondary steering pump is installed together with the secondary steering motor at the back of the hydraulic tank. It
supplies oil to the steering circuit if the steering circuit pressure decreases below the specified value.
HD465-8, HD605-8 10-255

SECONDARY STEERING MOTOR

STRUCTURE OF SECONDARY STEERING MOTOR
General view
1: Terminal E 2: Terminal M
SPECIFICATIONS OF SECONDARY STEERING MOTOR
Type: DC motor
Rated voltage: 24 V
Rated output: 0.9 kW
FUNCTION OF SECONDARY STEERING MOTOR
The secondary steering motor operates the secondary steering pump corresponding to the signals from the work equipment
controller when the engine stops or the steering circuit pressure decreases below the specified level.
10-256 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION BRAKE SYSTEM DIAGRAM
BRAKE SYSTEM
BRAKE SYSTEM DIAGRAM
HD465-8, HD605-8 10-257

BRAKE SYSTEM DIAGRAM 10 STRUCTURE AND FUNCTION
1: Front brake cut-off valve 7: Accumulator (front)

2: Relay valve 8: Accumulator charge valve
3: Secondary brake valve 9: Parking brake valve
4: Brake valve 10: Proportion pressure reducing valve (retarder)
5: Accumulator (park) 11: Slack adjuster
6: Accumulator (rear)
10-258 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION RETARDER CONTROL
RETARDER CONTROL
RETARDER CONTROL SYSTEM DIAGRAM
A: From brake valve
1. Rear wheel brake (right) 6. Hydraulic pump

2. Slack adjuster 7. Accumulator charge valve
3. Rear wheel brake (left) 8. Parking brake accumulator
4. Retarder and hoist controller 9. Electromagnetic proportion pressure reducing valve
5. Retarder control potentiometer
FUNCTION OF RETARDER CONTROL

Retarder lever control
The operation angle of the retarder lever is sensed with a potentiometer. A current corresponding to it is output to the proportion
pressure decrease solenoid valve to operate the retarder.
Retarder control for overrun prevention and transmission proper use

The proportion solenoid valve is controlled to operate the retarder corresponding to the command of the transmission controller.
HD465-8, HD605-8 10-259

ARSC SYSTEM 10 STRUCTURE AND FUNCTION
ARSC SYSTEM
ARSC
Abbreviation for Automatic Retarder Accelerator Control
ARCS SYSTEM DIAGRAM
1: Retarder and hoist controller 7: Transmission output signal

2: Retarder solenoid 8: Accelerator potentiometer
3: ARSC operation ON/OFF 9: Engine controller
4: Retarder brake signal 10: Transmission controller
5: Retarder lever signal 11: Monitor controller
6: ARSC vehicle speed setting switch 12: ARSC setting ON/OFF (set on the monitor)
FUNCTION OF ARSC SYSTEM
q With the ARSC setting (automatic retarder setting) ON, push the ARSC speed setting switch to the speed you want to main-
tain during downhill travel. The retarder automatically operates not to exceed the speed.
q The machine can travel downhill with ARSC function only and the target speed operated with the ARSC setting lever. Re-
tarder brake operation can be added with retarder lever.
REMARK
q When both of ARSC function and retarder brake by retarder lever operation are operated, the operation with larger braking
force has a priority. You may feel that the retarder lever movement is large while ARSC function is operated.
q Braking capacity with ARAS function can be examined with the monitor function. (Code: 33806)
q When ARAC setting is turned off or accelerator pedal is operated, if the travel speed lowers, cancel ARSC function.
q When an error is sensed to the related sensor, or communication error is sensed, cancel ARSC function.
10-260 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION BRAKE SYSTEM COMPONENTS
BRAKE SYSTEM COMPONENTS

BRAKE CHARGE PUMP
STRUCTURE OF BRAKE CHARGE PUMP
General view
A: To brake oil filter B: From brake sub-tank

SPECIFICATIONS OF BRAKE CHARGE PUMP
Brake charge pump
Model: SAR (1)18
Type: Gear pump
Theoretical released volume: 25.7 cm3/rev
FUNCTION OF BRAKE CHARGE PUMP
q The brake charge pump is installed on the rear of the radiator fan pump at the bottom of PTO case and is operated by the
engine.
q The brake charge pump pulls oil from the brake sub-tank and sends it to the brake circuit.
HD465-8, HD605-8 10-261

BRAKE SYSTEM COMPONENTS 10 STRUCTURE AND FUNCTION
PARKING BRAKE SOLENOID VALVE

STRUCTURE OF PARKING BRAKE SOLENOID VALVE
B: To parking brake T: To brake sub-tank

P: From secondary brake valve
1. Connector 2. Solenoid
FUNCTION OF PARKING BRAKE SOLENOID VALVE

Parking solenoid is installed between the secondary brake valve and rear brake. When the parking brake switch is set to
"PARK" position, the solenoid valve is set to off and the hydraulic pressure is released.
The parking brake is applied by spring force.
10-262 HD465-8, HD605-8

ACCUMULATOR CHARGE VALVE

STRUCTURE OF ACCUMULATOR CHARGE VALVE
ACC: To accumulator H1: Relief valve

P: From hydraulic pump R1: Relief valve
PP: From accumulator R3: Main relief valve
T: To brake sub-tank
HD465-8, HD605-8 10-263

1. Main relief valve (R3) 4. Relief valve (H1)

2. Valve body 5. Filter
3. Relief valve (R1) 6. Filter
SPECIFICATIONS OF ACCUMULATOR CHARGE VALVE

Cut-in pressure: 14.2 MPa {145 kg/cm2}
Cut-out pressure: 20.6 MPa {210 kg/cm2}
FUNCTION OF ACCUMULATOR CHARGE VALVE
q The accumulator charge valve maintains the oil pressure from the pump at the set pressure and accumulates the pressure
in the accumulator.
q If the oil pressure exceeds the set pressure, the oil from pump is transmitted to the drain circuit to reduce the load on the
pump.
10-264 HD465-8, HD605-8

OPERATION OF ACCUMULATOR CHARGE VALVE

When oil is not supplied to accumulator (Cut-out condition)
1. Since the pressure at port (B) is higher than the set pressure of
relief valve (R1), piston (8) moves up by the oil pressure of port
(B). As a result, poppet (6) opens and port (C) is connected to
port (T).
2. Since the spring chamber at the right of spool (15) is connected
to port (C) of relief valve (R1), the pressure in it becomes the tank
pressure. The oil from the pump goes into port (P), pushes spool
(15) to the right at a low-pressure equivalent to the load on spring
(14). It also goes through orifices (17), (18), and (16), and flows
to the tank.
When oil is supplied to accumulator

1) Cut-in condition
1. When the pressure at port (B) decreases below the set pressure
of relief valve (R1), piston (8) is pushed back down by spring (5).
As a result, poppet (6) touches valve seat (7) to disconnect port
(C) from port (T).
2. The right spring chamber of spool (15) is disconnected from port
(T) and the pressure in it increases. The pressure in port (P) also
increases.
3. When pressure at port (P) goes below the pressure at port (B)
(accumulator pressure), oil supply to the accumulator starts. In
this case, it is decided by the dimension (area) of orifice (17). The
pressure difference (equivalent to the load on spring (14)) gener-
ated on the two sides of the orifice. Set quantity is supplied
regardless of the engine speed.
HD465-8, HD605-8 10-265

2) After oil pressure gets to cut-in condition

1. When pressure at port (B) (accumulator pressure) gets to the set
pressure of relief valve (R1), poppet (6) leaves valve seat (7). As
a result, oil flows and is relieved.
2. As the oil is relieved, pressure difference is generated across
piston (8). As a result, piston (8) moves to open poppet (6) and
connect port (C) to port (T).
3. Since the spring chamber at the right of spool (15) is connected
to port (C) of relief valve (R1), the pressure in it becomes the tank
pressure.
4. Since the pressure at port (P) also decreases to the level equiv-
alent to the load of spring (14), oil supply to port (B) is stopped.
Main relief valve (R3)

If the pressure at port (P) (pump pressure) exceeds the set pressure
of relief valve (R3), the oil from the pump pushes up ball (11) against
spring (3) to supply the oil into the tank circuit. The maximum pres-
sure in the brake circuit is small for protection of the circuit.
10-266 HD465-8, HD605-8

BRAKE CIRCUIT ACCUMULATOR

STRUCTURE OF BRAKE CIRCUIT ACCUMULATOR
1. Valve 3. Cylinder
2. Top cover 4. Piston
SPECIFICATIONS OF BRAKE CIRCUIT ACCUMULATOR

Front brake
Gas used: Nitrogen gas
Charge quantity: 3,500 cc
Charge pressure: 11.8 MPa {120 kg/cm2}
Rear brake, parking brake

Gas used: Nitrogen gas
Charge quantity: 4,000 cc
Charge pressure: 6.9 MPa {70 kg/cm2}
FUNCTION OF BRAKE CIRCUIT ACCUMULATOR

The accumulator is installed between the accumulator charge valve and the brake valve. It is charged with nitrogen gas be-
tween cylinder (3) and free piston (4), and uses the compressed gas to absorb the pulse of the hydraulic pump. If the engine
stops, the pressure from the hydraulic pump disappears, so the accumulator uses its stored pressure for brake force.
HD465-8, HD605-8 10-267

BRAKE VALVE
STRUCTURE OF BRAKE VALVE
A: To rear brake D: From front accumulator

B: To front brake E: From rear accumulator
C: To brake sub-tank
1: Pilot piston 4: Spool
2: Rod 5: Upper cylinder
3: Lower cylinder 6: Spool
10-268 HD465-8, HD605-8

OPERATION OF BRAKE VALVE

q Upper part of valve
When the brake pedal (1) is depressed, the pedal force is trans-
mitted to spool (3) through rod (2) and spring (4). When spool (3)
lowers, drain port (a) is closed. The oil from the pump and accu-
mulator flows from port (PA) to port (A) and operates the rear
brake cylinder.
q Lower part of valve
When the brake pedal (1) is depressed, the pedal force is trans-
mitted to spool (3) through rod (2) and spring (4). When spool (3)
lowers, spool (5) is also pushed down by plunger (6). When this
happens, drain port (b) is closed. The oil from the pump and ac-
cumulator flows from port (PB) to port (B) and operates the front
brake cylinders.
q Operation of brake when upper part of valve has trouble

If oil leaks from the upper part of the valve, the lower part of the
valve operates usually with spool (5) moved down mechanically
when pedal (1) is depressed. The brake of the upper part of the
valve does not operate.
q Operation of brake when lower part of valve has trouble
If the oil leaks from the lower part of the valve, the brake of the
upper part of the valve operates correctly.
HD465-8, HD605-8 10-269

Balance operation
When oil fills the rear brake cylinder and the pressure between
ports (PA) and (A) increases, the oil flowing in port (H) through
orifice (e) of spool (3) pushes up spool (3) against spring (4) to
disconnect ports (PA) and (A). At this time, drain port (a) is kept
closed to maintain the oil in the brake cylinder and leave the
brake applied.
1) When spool (3) in the upper part of the valve moves up and
the circuit between port (PA) and port (A) is shut off, oil also
fills the front brake cylinder at the same time. The pressure in
the circuit between port (PB) and port (B) rises. The oil that
enters port (J) from orifice (f) of spool (5) pushes up spool by
the same amount that spool (3) moves, and shuts off port
(PB) and port (B). Drain port (b) is closed, so the oil that
enters the brake cylinder is held, and the brake is applied.
2) The pressure in the upper part of the valve is balanced with
the depressing force of the pedal. The pressure in the the
lower part of the valve is balanced with the pressure in the
space of the upper part. When spools (3) and (5) move to the
travel end, ports (PA) and (A), and ports (PB) and (B) are
connected completely. Thus, the pressures in the upper and
lower parts and in the right and left brake cylinders become
equal to the pressure from the pump. Therefore, the brake is adjusted by the change in depressing force of the pedal
until the piston moves to the travel end.
When the brake is released

When the pedal (1) is released and the depressing force is re-
moved from the top of the spool, the pressure from the brake cyl-
inder and the force of the spool spring moves spool (3) up. Drain
port (a) is opened and the oil from the brake cylinder flows to the
brake tank circuit to release the rear brake.
When the pedal is released, spool (3) of the upper part of the
valve moves up. The pressure from the brake cylinder and the
spool spring moves spool (5) to open drain port (b). Then, the oil
from the brake cylinder flows to the brake tank circuit to release
the front brake.
10-270 HD465-8, HD605-8

SECONDARY BRAKE VALVE

STRUCTURE OF SECONDARY BRAKE VALVE
A: To parking brake valve T: To brake sub-tank

P: From accumulator
1: Rod 3: Cylinder
2: Spool
FUNCTION OF SECONDARY BRAKE VALVE

q When the pedal is depressed, the parking brake pressure decreases, and the parking brake operates corresponding to the
pedal angle.
HD465-8, HD605-8 10-271

SECONDARY BRAKE RELAY VALVE

STRUCTURE OF SECONDARY BRAKE RELAY VALVE
A: To front brake PP: From secondary brake valve

P: From accumulator T: To brake sub-tank
1: Spool 3: Lower cylinder
2: Upper cylinder 4: Spool
FUNCTION OF SECONDARY BRAKE RELAY VALVE

This valve operates the front and rear brake corresponding to the parking brake pressure controlled by the secondary brake
pedal.
10-272 HD465-8, HD605-8

PROPORTION PRESSURE REDUCING VALVE

STRUCTURE OF PROPORTION PRESSURE REDUCING VALVE
A: To slack adjuster T: To brake system tank

P: From accumulator
1: Filter 3: Solenoid assembly
2: Connector
FUNCTION OF PROPORTION PRESSURE REDUCING VALVE

The proportion pressure reducing valve is used for retarder control and KTCS and installed between the brake system tank
and brake valve in the brake circuit.
It changes the hydraulic released volume pressure to control the retarder freely corresponding to the angle of the retarder con-
trol lever or input from the KTCS.
HD465-8, HD605-8 10-273

SLACK ADJUSTER
STRUCTURE OF SLACK ADJUSTER
A: In port B: Out port
1: Cylinder 3: Piston
2: Check valve
SPECIFICATIONS OF SLACK ADJUSTER

Piston operation pressure: 9.8 to 19.6 kPa {0.1 to 0.2 kg/cm2}
Check valve open pressure (When cooling pressure is 0): 1.74±0.05 MPa {17.8± 0.5 kg/cm2}
Check valve close pressure: 1.09±0.05 MPa {11.1± 0.5 kg/cm2}
FUNCTION OF SLACK ADJUSTER

The slack adjuster is installed in the brake oil line that go to the brake piston from the brake valve. It keeps the time at brake
operation at a constant value.
10-274 HD465-8, HD605-8

OPERATION OF SLACK ADJUSTER

Operation when brake pedal is depressed
1. Before the brake is depressed, pistons (4) goes back by travels
(S) (all strokes). When the brake pedal is depressed, oil released
from the brake valve branches into right and left cylinders (2)
through port (P) of the slack adjuster and move pistons (4) by
travel (S) to the right and the left.
2. As a result, brake pistons (7) move by travel (S). At this time, the
clearance between each piston and the disc is reduced to zero,
but no brake force is generated.
3. When the brake pedal is depressed further and the oil pressure
from the brake valve exceeds the specified pressure, check
valve (3) opens and pressure is applied to port (C) to generate
brake force.
Thus, the time when the brake is applied is maintained constant.
Operation when brake pedal is released

When the brake pedal is released, pistons (4) goes back as the brake
oil pressure by the oil volume for travel (S), and the brake is released.
That is, back travel (T) of brake pistons (7) is decided by the oil vol-
ume for travel (S) of the slack adjuster and the time in brake force is
constant, regardless of wear of the brake disc.
HD465-8, HD605-8 10-275

BRAKE
STRUCTURE OF FRONT BRAKE
Section view
1: Piston 3: Disc
2: Pad
FUNCTION OF FRONT BRAKE
The front brake is a dry-type one disc and operates by piston.
10-276 HD465-8, HD605-8

STRUCTURE OF REAR BRAKE

Section view
1: Inner gear 6: Damper

2: Retainer 7: Piston
3: Outer gear 8: Spring (for parking brake)
4: Plate 9: Cylinder
5: Disc 10: Piston (for parking brake)
HD465-8, HD605-8 10-277

FUNCTION OF REAR BRAKE

The rear brake is an oil cool disc type, and it operates as a spring applied parking brake.
OPERATION OF REAR BRAKE

1. When the brake pedal is depressed, the pressurized oil from the
brake valve moves brake piston (7) in the direction of the arrow
to press discs (5) against plates (4) and generate force between
them. Since the wheel turns together with the discs, the force
decelerates the machine to stop.
A: From slack adjuster
2. When the brake pedal is released, back pressure on brake piston

(7) is released. The force of the internal pressure moves the
piston to the left to release the brake.
B: To slack adjuster
10-278 HD465-8, HD605-8

PARKING BRAKE
STRUCTURE OF PARKING BRAKE
Section view
1: Inner gear 6: Damper

2: Retainer 7: Piston
3: Outer gear 8: Spring (for parking brake)
4: Plate 9: Cylinder
5: Disc 10: Piston (for parking brake)
HD465-8, HD605-8 10-279

FUNCTION OF PARKING BRAKE

The parking brake is an oil cool disc type, and it operates by a spring.
OPERATION OF PARKING BRAKE

1. The parking brake contained in the rear brake is structurally
designed to operate mechanically by spring (8) force and to be
released by hydraulic pressure.
2. The park release hydraulic pressure acts on the parking brake
piston (8) from the accumulator through the secondary brake
valve and parking brake solenoid.
3. With the parking brake switch in the travel position, the hydraulic
pressure releases the parking brake by push of the parking brake
piston (10) and compresses the spring (8).
A: From parking brake solenoid
4. With the parking brake switch in the park position, the parking
brake solenoid is not energized and the park brake hydraulic
pressure is released. Then, the parking brake is engaged
through the parking brake piston (10), brake piston (7), plate (4),
and disk (5) pushed by spring (8) force.
B: To parking brake solenoid
10-280 HD465-8, HD605-8

BRAKE SUB-TANK
STRUCTURE OF BRAKE SUB-TANK
A: From accumulator charge valve, brake valve, and propor- C: To hydraulic pump
tion pressure reducing valve
B: To transmission
1: In pipe 3: Oil level gauge
2: Valve
HD465-8, HD605-8 10-281

ABS 10 STRUCTURE AND FUNCTION
ABS
ABS
Abbreviation for Antilock Brake System
ABS SYSTEM DIAGRAM
(For machine with ABS)
1: ABS controller 4: ABS control valve (rear)

2: ABS ON/OFF valve (front) (*1) 5: ABS control valve (front)
3: ABS ON/OFF valve (rear)
*1: Use together with front brake cut off valve
10-282 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION ABS
ABS SYSTEM DIAGRAM
1: ABS controller 3: Transmission controller

2: Retarder and hoist controller 4: Engine controller
HD465-8, HD605-8 10-283

5: Monitor controller 21: Wheel speed sensor (RL)

6: ABS control valve (FL) 22: Wheel speed sensor (RR)
7: ABS control valve (FR) 23: Retarder pressure sensor
8: ABS control valve (RL) 24: Service brake pressure switch
9: ABS control valve (RR) 25: Retarder lever signal
10: ABS ON/OFF valve (F) 26: Front brake cut ON/OFF switch
11: ABS ON/OFF valve (R) 27: Parking brake pressure sensor
12: ABS ON/OFF valve pressure switch (F) 28: Transmission output speed sensor
13: ABS ON/OFF valve pressure switch (R) 29: Gear shift lever
14: ABS pressure sensor (FL) 30: Accelerator potentiometer
15: ABS pressure sensor (FR) 31: Engine speed sensor
16: ABS pressure sensor (RL) 32: Engine coolant temperature sensor
17: ABS pressure sensor (RR) 33: Ambient pressure sensor
18: ABS ON/OFF valve pressure sensor 34: ABS setting ON/OFF (set on the monitor)
19: Wheel speed sensor (FL) 35: ABS system check command (set on the monitor)
20: Wheel speed sensor (FR) 36: Ambient temperature
FUNCTION OF ABS
q The ABS is a brake system that ensures the steering ability and stable machine posture. It works by automatically sup-
pressing the skidding caused by the wheels locking when the brakes are applied suddenly or are applied on snow-covered
roads or other slippery road surfaces.
q ABS controller calculates the wheel speed and pseudo machine travel speed according to the signals from the wheel speed
sensors attached to each wheel, and sends control signals to the control valves of wheels that have tendency to lock, there-
by controlling brakes for four wheels separately.
REMARK
q When ABS operates on a slippery road surface, the stopping distance may be longer.
q During low speed operation, wheels may lock.
OPERATION OF ABS
ABS system logic
ABS
Measurement of each wheel
Wheel speed sensor
rotational speed
Calculation of absolute travel

ABS: ABS controller
speed
Calculation of each wheel slip
ratio
Reduction of each brake oil

Control valve
pressure for slipping wheel
10-284 HD465-8, HD605-8

V: Machine velocity λ1: Slip ratio

V (Ref): Calculated machine velocity Signal shows that the wheel rotational speed is the
V (Rad): Wheel rotational speed smaller than travel speed and exceeds the stipulated
a0: Rate of speed increase (-) limit
Signal shows that deceleration exceeds the set limit
a1: Rate of speed increase
Signal shows that acceleration exceeds the set limit
HD465-8, HD605-8 10-285

When not operated (normal braking)

When there is no tendency for the wheel to lock by the normal braking operation, the ABS control valve does not work and
hydraulic pressure is directly supplied to the slack adjuster from the brake valve.
During operation
q Hydraulic pressure on the brake is controlled as shown by the graph, which prevents the wheel from locking.
t1: Controls are started and wheel rotational speed shows a tendency to lock as braking starts to take effect on the wheel.
t2: When the wheel deceleration has passed [a0], the controller keeps the electrical signal at the constant level to observe
the situation since the wheel may become unstable.
t3: When the wheel speed decreases and has reached the slip rate (λ1), the controller judges that the wheel is unstable
and change the electrical signal to release the brake.
t4: With the brake released, the wheel rotational speed shows signs of recovery. When the wheel deceleration has passed
[a0], the controller judges that the wheel is stable and keeps the electrical signal at the constant level.
t5, t6: With the brake pressure held, the wheel acceleration passes [a1] then decreases and returns to [a1] again.
Judging that the wheel acceleration is stabilized, the controller change the electrical signal to activate the brake.
Changing the signal is performed gradually so as not to change the wheel rotational speed significantly. (Judging that
the road surface is likely to cause wheel lock)
t7: With the brake activated, the wheel rotational speed shows a tendency to lock again. When the deceleration has passed
[a0], the controller judges that the wheel is unstable and changes the electrical signal to release the brake. The controller
judges that the wheel is unstable and change the electrical signal to release the brake.
t8: With the brake released, the wheel rotational speed shows signs of recovery. When the wheel deceleration has returned
to [a0] again, the controller judges that the wheel is stable and keeps the electrical signal at the constant level.
t9: Same as t6.
Repeat t4 to t9.
10-286 HD465-8, HD605-8

COMPONENT PARTS OF ABS

ABS CONTROL VALVE
STRUCTURE OF ABS CONTROL VALVE
A: To slack adjuster T: To brake sub-tank

P: From brake valve
1: Filter 3: Solenoid assembly
2: Connector
FUNCTION OF ABS CONTROL VALVE
q ABS control valve is attached between the brake valve and slack adjuster.
q The braking force is controlled by changing the hydraulic discharged volume according to the electrical output from the ABS
controller.
HD465-8, HD605-8 10-287

ABS ON/OFF VALVE

STRUCTURE OF FRONT ABS ON/OFF VALVE
A: To slack adjuster T: To brake sub-tank

P: From brake valve
1: Connector 2: Solenoid
10-288 HD465-8, HD605-8

STRUCTURE OF REAR ABS ON/OFF VALVE
A: To slack adjuster 1: Connector

P: From proportional pressure reducing valve 2: Solenoid assembly
T: To brake sub-tank
FUNCTION OF ABS ON/OFF VALVE

q ABS ON/OFF valve is attached between the brake valve and slack adjuster.
q When the ABS setting is enabled, the solenoid valve is energized and the ABS hydraulic circuit is activated.
q When the ABS setting is disabled, the solenoid valve is de-energized while the output of ABS control valve is minimized,
and the ABS hydraulic circuit is deactivated.
HD465-8, HD605-8 10-289

AUTO-GREASING SYSTEM DIAGRAM 10 STRUCTURE AND FUNCTION
AUTO-GREASING SYSTEM
(For machine with auto-greasing system)
AUTO-GREASING SYSTEM DIAGRAM
10-290 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION AUTO-GREASING SYSTEM DIAGRAM
HD465-8, HD605-8 10-291

AUTO-GREASING SYSTEM DIAGRAM 10 STRUCTURE AND FUNCTION
1: Grease pump 8: Tie rod

2: Grease tank 9: Steering cylinder
3: Controller 10: Radius rod
4: Manual lubrication switch 11: Body hinge pin
5: A-frame 12: Center lever
6: Front suspension 13: Hoist cylinder
7: Rear suspension
Auto-greasing injector circulation points

L1: Front suspension L.H. upper R19: Hoist cylinder (lower right)
L2: Center lever R.H. R20: Radius rod (lower right front)
L3: Tie rod end (left) L21: Radius rod (lower left front)
L4: Steering cylinder end (left) L22: Hoist cylinder (lower left)
L5: A-frame (left) L23: Hoist cylinder (upper left)
R6: Center lever R24: Dump body hinge pin (right)
R7: Steering cylinder frame (right) R25: Rear suspension (lower right)
L8: Steering cylinder frame (left) R26: Rear suspension (upper right)
L9: Center lever (left) R27: Radius rod (upper right rear)
L10: A-frame (left rear) R28: Radius rod (upper right front)
L11: A-frame (left front) R29: Radius rod (lower right rear)
R12: A-frame (right front) L30: Radius rod (lower left rear)
R13: A-frame (right rear) L31: Radius rod (upper left front)
R14: Tie rod end (right) L32: Radius rod (upper left rear)
R15: A-frame (right) L33: Rear suspension (upper left)
R16: Steering cylinder end (right) L34: Rear suspension (lower left)
R17: Front suspension (upper right) L35: Dump body hinge pin (left)
R18: Hoist cylinder (upper right)
10-292 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION AUTO-GREASING SYSTEM DIAGRAM
AUTO-GREASING SYSTEM DIAGRAM
L = hose length
1: L1 L = 1298 mm Front suspension (upper left) 20: R26 L = 618 mm Rear suspension (upper right)
2: L2 L = 1988 mm Center lever (right) 21: R25 L = 1568 mm Rear suspension (lower right)
3: L3 L = 1563 mm Tie rod end (left) 22: R27 L = 1033 mm Radius rod (upper right rear)
4: L4 L = 1533 mm Steering cylinder end (left) 23: R29 L = 1528 mm Radius rod (lower right rear)
5: L5 L = 1963 mm A-frame (left) 24: R19 L = 3793 mm Hoist cylinder (lower right)
6: L8 L = 2028 mm Steering cylinder frame (left) 25: R20 L = 3568 mm Radius rod (lower right front)
7: L9 L = 2003 mm Center lever (left) 26: R28 L = 1993 mm Radius rod (upper right front)
8: L11 L = 1768 mm A-frame (left front) 27: L31 L = 1748 mm Radius rod (upper left front)
9: L10 L = 1143 mm A-frame (left rear) 28: L21 L = 3193 mm Radius rod (lower left front)
10: R17 L = 1068 mm Front suspension (upper right) 29: L22 L = 3418 mm Hoist cylinder (lower left)
11: R16 L = 1528 mm Steering cylinder end (right) 30: L30 L = 1528 mm Radius rod (lower left rear)
12: R15 L = 1968 mm A-frame (right) 31: L32 L = 1033 mm Radius rod (upper left rear)
13: R14 L = 1563 mm Tie rod end (left) 32: L34 L = 1568 mm Rear suspension (lower left)
14: R13 L = 1123 mm A-frame (right rear) 33: L33 L = 618 mm Rear suspension (upper left)
15: R12 L = 1653 mm A-frame (right front) 34: L35 L = 498 mm Dump body hinge pin (left)
16: R7 L = 998 mm Steering cylinder frame (right) 35: L23 L = 858 mm Hoist cylinder (upper left)
17: R6 L = 988 mm Center lever 36: Auto-greasing pump
18: R18 L = 858 mm Hoist cylinder (upper right) 37: Auto-greasing injector
19: R24 L = 498 mm Dump body hinge pin (right)
FUNCTION OF AUTO-GREASING SYSTEM
q When the start switch is set to ON position, the auto-greasing system supplies grease according to the set time of the timer.
q If the manual lubrication switch on the dashboard is pressed, the auto-greasing system starts supplying grease, regardless
of the set time of the timer.
REMARK
q For how to operate the auto-greasing system, see the Operation and Maintenance Manual.
HD465-8, HD605-8 10-293

COMPONENT PARTS OF AUTO-GREASING SYSTEM 10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF AUTO-GREASING SYSTEM

AUTO-GREASING PUMP
STRUCTURE OF AUTO-GREASING PUMP
1: Tank 6: Connector (motor, controller)

2: Auto-greasing pump (with built-in motor) 7: Display
3: Controller 8: Change switch
4: Relief valve 9: Enter switch
5: Filter
10-294 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF AUTO-GREASING SYSTEM
SPECIFICATIONS OF AUTO-GREASING PUMP

Model: 80090
Max. voltage: 24 V
Max. current value: 10 A
Temperature range for operation: -40 to 70 °C
Discharged volume: 24.6 cc/min (pressure 24 MPa {245kg/cm2})
Grease capacity: 8 l
Grease to be used: NLGI No.2 or equivalent
AUTO-GREASING INJECTOR
STRUCTURE OF AUTO-GREASING INJECTOR
Right side of machine
1: Manifold 5: Indicator stem

2: Injector 6: Adjusting screw
3: Slide valve 7: Spring
4: Piston
A: Grease inlet port
B: Grease outlet port
HD465-8, HD605-8 10-295

Left side of machine

4: Piston
A: Grease inlet port B: Grease outlet port
Rear side of machine

4: Piston
A: Grease inlet port B: Grease outlet port
10-296 HD465-8, HD605-8

SPECIFICATIONS OF AUTO-GREASING INJECTOR

Max. using pressure: 41.3 MPa {421 kg/cm2}
Normal using pressure: 21.0 MPa {214 kg/cm2}
Temperature range for operation: -40 to 80 °C
Grease discharged volume range: 0.25 to 1.31 cc
OPERATION OF AUTO-GREASING INJECTOR
q The grease enters the inlet port and then is distributed to both
sides of piston (4) through the slide valve (3).
q The piston (4) is moved down by the grease pressure which en-
ters the inlet port and acts on both sides of the piston (4) and then
the chamber (A) is filled with the grease.
q The indicator shaft (5) is pulled into a position farthest from the
stopper of the adjusting screw (6).
HD465-8, HD605-8 10-297

q If more pressure is applied, the slide valve (3) moves against the
force of the spring (7).
q As the slide valve (3) moves, the passage (B) is closed and the
passage (D) to the outlet port (C) is opened.
Under this condition, the grease pressure from the inlet port acts
on only the bottom of the piston.
q The grease from the inlet port moves the piston (4) and then the
piston (4) sends the grease in chamber (A) forcibly to each lubri-
cation point through the passage (D), slide valve (3) and outlet
port (C).
q The piston (4) sends out the grease until the indicator shaft (5)
touches the stopper of the adjusting screw (6).
q The amount of the grease sent out can be adjusted by limiting the
piston movement.
q The piston (4) and slide valve (3) stay at the current positions un-
til the supply line grease pressure is released.
10-298 HD465-8, HD605-8

q If the supply line grease pressure lowers to 6.9MPa {70 kg/cm2},

the slide valve (3) moves down to close the passage (D) and
open the passage (B). Then, the supply line grease pressure
acts on both sides of the piston (4) to move the piston (4) down.
q As the piston (4) moves down, a certain amount of the grease
flows from the lower side of the piston (4) to the upper side of the
piston (4) through the slide valve (3) and passage (B).
q Since the volume of the upper side of the piston is greater than
that of the lower side, excessive grease flows from the supply line
to the upper side of the piston. The pressure lowers quickly be-
cause of the grease leaving from the supply line.
q The piston (4) may or may not fully return, depending on the vol-
ume of the grease in the supply line. The injector is now ready for
the next cycle.
HD465-8, HD605-8 10-299

SUSPENSION 10 STRUCTURE AND FUNCTION
UNDERCARRIAGE AND FRAME

SUSPENSION
STRUCTURE OF SUSPENSION
1. Front suspension cylinder 3. Radius rod (Upper rod)

2. Radius rod (Lower rod) 4. Rear suspension cylinder
FUNCTION OF SUSPENSION
q The suspension system supports the weight of the machine, absorbs the shocks from the rough road surface. It improves
operator comfort, and maintains wheels contact to the road surface constantly to attain high movement performance.
q Hydro pneumatic cylinders are used for the suspension cylinders to reduce the shock. With hydro pneumatic cylinders, the
suspension cylinder is charged (sealed) with oil and nitrogen gas. Since the load from the road surface increases, the ni-
trogen gas is compressed/expanded and acts as a spring. The suspension cylinder is extended and retracted to make the
oil flow. In the thin area of oil flow hole, it increases restriction and acts as a shock absorber. When this happens, the sus-
pension cylinder has the function of a shock absorber.
q In addition to these functions, the front suspension employs an automatic suspension system. In this system, the force of
the suspension is automatically changed by the selection of damping force to match the travel conditions and load condi-
tions. This further increases the machine ride and ride comfort.
10-300 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION FRONT SUSPENSION
FRONT SUSPENSION
STRUCTURE OF FRONT SUSPENSION
B A
A A
Y Z
A - A
7
Y Z
A4 H1 2 6 0 1
A: Port A B: Port B
1. Feed valve 5. Air bleed valve
2. Cylinder 6. Tube
3. Rod 7. Valve assembly
4. Valve (for bleed air)
HD465-8, HD605-8 10-301

FRONT SUSPENSION 10 STRUCTURE AND FUNCTION
FUNCTION OF FRONT SUSPENSION

The front suspension functions as a shock absorber and spring. It is
connected by spherical bearings to the lower arm (A frame) and pri-
mary frame.
The lower arms and wheels are fluctuated corresponding to the sus-
pension cylinder to maintain the wheel align and improve the stable
of machine.
10-302 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION REAR SUSPENSION
REAR SUSPENSION
STRUCTURE OF REAR SUSPENSION
1 4
2 5
A4 H1 2 6 9 2
1. Feed valve 4. Valve (for bleed air and install pressure sensor)
2. Cylinder 5. Ball
3. Rod
HD465-8, HD605-8 10-303

REAR SUSPENSION 10 STRUCTURE AND FUNCTION
FUNCTION OF REAR SUSPENSION

The body supported by the frame, two radius rods at the lower side,
two V-shaped rods at the higher side, and two suspension cylinders.
Each edge is connected with spherical bearing.
It transmits the load and force through the top and bottom rods.
The V-shaped rods at the top also function to maintain the middle of
the machine (axle).
The use of the V-shaped rod improves the roll steering properties.
10-304 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION SUSPENSION CYLINDER
SUSPENSION CYLINDER
STRUCTURE OF SUSPENSION CYLINDER
1. Feed valve 6. Oil chamber

2. Space 7. Nitrogen gas chamber
3. Check ball 8. Cylinder rod
4. Orifice 9. Cylinder
5. Orifice 10. Air bleed valve
a: When extended b: When retracted

FUNCTION OF SUSPENSION CYLINDER
q The suspension cylinder has the functions for a shock absorber and a spring.
When oil is sent from oil chamber (6) through orifices (4) and (5) to space (2), the oil flow reduced by the orifices to give
dampen effect.
OPERATION OF SUSPENSION CYLINDER

1. Retraction action
When the machine travels and hits an object on the road, the wheels are pushed up, and the cylinder rod are pushed in
the cylinder.
When this happens, the nitrogen gas in chamber (7) is compressed, the oil in chamber (6) is sent through the two orifices
(4) and (5) to space (2), and space (2) is filled more quickly than when it extends.
2. Extend procedure
When the machine hits on any object on the road surface, the cylinder rod is pushed up by the weight of the wheels and
axle and the pressure of the nitrogen inside chamber (7).
As a result, the quantity of oil in space (2) decreases and pressure is applied to the oil that stay in space (2).
This pressurized oil closes orifice (4) with check ball (3), and is sent to chamber (6) through orifice (5). The flow of oil
through the orifice is controlled. In this procedure, the quantity of oil back to chamber (6) is restricted to provide a shock
absorb effect.
HD465-8, HD605-8 10-305

STRUCTURE OF WORK EQUIPMENT 10 STRUCTURE AND FUNCTION
WORK EQUIPMENT
STRUCTURE OF WORK EQUIPMENT
General view
1: Hoist cylinder (right) 3: Hoist cylinder (left)

2: Body
FUNCTION OF WORK EQUIPMENT

The body has functions of load, and unload by lift of the dump body with hoist cylinder.
10-306 HD465-8, HD605-8

10 STRUCTURE AND FUNCTION ROPS CAB
CAB AND ATTACHMENTS

ROPS CAB
ROPS
Abbreviation for Roll-Over Protection Structure
STRUCTURE OF ROPS CAB
General view
1: Front window wiper 5: Rear window

2: Front window 6: Window washer tank
3: Door (left) 7: Door (right)
4: Air conditioner fresh air filter
FUNCTION OF ROPS CAB

ROPS cab is to protect the operator which wears a seat belt from injury when the machine rolls over.
HD465-8, HD605-8 10-307

CAB MOUNT 10 STRUCTURE AND FUNCTION
CAB MOUNT
STRUCTURE OF CAB MOUNT
General view
1: Viscous mount (front) 3: Viscous mount (rear)

2: ROPS stop (front) 4: ROPS stop (rear)
q Two mounts are installed at the front and two at the rear to attach the floor frame and cab.
q Two ROPS stop (2) and (4) are installed at the front and two at the rear to attach the cab with the built in ROPS in case the
machine rolls over.
FUNCTION OF CAB MOUNT

The oil sealed type is used to damper vibration so the vibration is not transmitted to the operator if the machine vibrates.
10-308 HD465-8, HD605-8

20 STANDARD VALUE TABLE
HD465-8, HD605-8 20-1

CONTENTS 20 STANDARD VALUE TABLE
CONTENTS
ABBREVIATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20-3
STANDARD VALUE TABLE FOR ENGINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20-8
STANDARD VALUE TABLE FOR MACHINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20-14
MACHINE SETTING AND PROCEDURE TO MEASURE PERFORMANCE - - - - - - - - - - - - - - - - - - - - - - - - - 20-40
20-2 HD465-8, HD605-8

20 STANDARD VALUE TABLE ABBREVIATIONS
ABBREVIATIONS

and system)

System

Advanced Joystick
Automatic Retarder
Automatic Retarder
the operator.




CDR Engine

Closed-center Load
Sensing System


HD465-8, HD605-8 20-3

ABBREVIATIONS 20 STANDARD VALUE TABLE

and system)

Electronic Control



Exhaust Gas
Recirculation



FOPS Cab and canopy
Structure

Global Positioning
System
Plus) location.

Global Navigation
Satellite System
Plus) location.

HSS

Hydro Static

Communication and
electronic control



20-4 HD465-8, HD605-8


and system)

KCCV Engine
filters.

KCSF Engine

KOMATSU Diesel
Oxidation Catalyst
muffler.

KDPF Engine
Particulate Filter
muffler.
KOMATSU Traction

such as a monitor.

LIN

load.
LVDS


Service
cell phones.

system
activated.

system
activated.
HD465-8, HD605-8 20-5

ABBREVIATIONS 20 STANDARD VALUE TABLE

and system)

PCCS
transmission.

supply pump.

Hydraulic system
(D, PC, etc)
PTP

ROPS Cab and canopy
Structure
ISO 12117-2.

SCR Urea SCR system
of related devices.



Tip-Over Protective
Structure
overturning)

VGT Engine

Variable HorsePower
Control
of the machine.

D: Bulldozer
HD: Dump truck
WA: Wheel loader
20-6 HD465-8, HD605-8

A/C Air Conditioner
A/M Air Mix damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
ENG Engine
F.G. Frame Ground
GND Ground
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/M Transmission
HD465-8, HD605-8 20-7

STANDARD VALUE TABLE FOR ENGINE: HD465-8 20 STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR ENGINE

STANDARD VALUE TABLE FOR ENGINE: HD465-8
Performance

Engine SAA6D170E-7
Standard value
Item Test condition Unit for new Repair limit
machine
q Engine coolant temperature: 60 to 100 °C
Engine speed q Hydraulic oil temperature: 45 to 55 °C
rpm 2270±50 2270±50
at high idle q Torque converter oil temperature: 60 to 80 °C
q Accelerator pedal: Depress to travel stop (High idle)
q Engine coolant temperature: 65 AISS LOW switch: ON rpm 750±50 750±50
to 100 °C
q Hydraulic oil temperature: 45 to
Engine speed 55 °C
at low idle q Torque converter oil temperature: AISS LOW switch: rpm 1100±50 1100±50
60 to 80 °C OFF
q Accelerator pedal: Not depressed
(Low idle)
Air intake and exhaust system

Engine SAA6D170E-7
Standard value
machine
q Engine coolant temperature: 60 Min. 166 Min. 149
Gauge pressure
to 100 °C {Min. 1245} {Min. 1118}
q Torque converter oil temperature:
60 to 80 °C
q With torque converter stalled
Boost REMARK kPa
pressure q The gauge pressure does not in- {mmHg} Min. 267.3 Min. 250.3
Absolute pressure
clude atmospheric pressure. {Min. 2005} {Min. 1878}
q The absolute pressure is the sum
of the gauge pressure and atmo-
spheric pressure of 101.3 kPa
{760 mmHg} at sea level.
q Full speed range (ambient temperature 20 °C)
Exhaust
q Hydraulic oil temperature: 45 to 55 °C °C Max. 700 Max. 700
temperature
q Torque converter oil temperature: 60 to 80 °C
20-8 HD465-8, HD605-8

20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR ENGINE: HD465-8

Engine SAA6D170E-7
Standard value
machine
q Engine cool- Accelerator pedal:
ant tempera- Measured at Depress to travel stop Max. 1.0 Max. 2.5
ture: 60 to measuring port of (High idle)
100 °C KDPF inlet piping With torque converter
q After it is kept Max. 1.5 Max. 2.5
Exhaust gas at normal stalled Bosch
color condition for 5 Accelerator pedal: index
seconds Depress to travel stop Max. 0.5 Max. 0.5
Torque con- Measured at
q (High idle)
verter oil tem- exhaust pipe
perature: 60 outlet With torque converter
Max. 0.5 Max. 0.5
to 80 °C stalled
Valve Engine coolant temperature: Normal Intake valve 0.32 -

mm
clearance temperature Exhaust valve 0.62 -
Accelerator pedal:
EGR valve oil Engine coolant temperature: 60 to Min. 1.80 Min. 1.80
Depress to travel stop
pressure, 100 °C MPa {Min. 18.4} {Min. 18.4}
(High idle)
VGT oil {kg/cm2}
pressure Engine coolant temperature: 65 to Accelerator pedal: Not Min. 1.18 Min. 1.18
100 °C depressed (Low idle) {Min. 12} {Min. 12}
Main body

Engine SAA6D170E-7
Standard value
machine
Compression q Engine oil temperature: 40 to 60 °C MPa Min. 2.94 Min. 2.1

pressure q At start (engine speed): 210 to 250 rpm (reference) {kg/cm2} {Min. 30} {Min. 21}

Blowby kPa Max. 3.43 Max. 9.41
pressure {mmH2O} {Max. 350} {Max. 960}
Fuel system

Engine SAA6D170E-7
Standard value
machine
q Engine coolant temperature: 60 to 100 °C MPa 0.15 to 0.3 0.15 to 0.3
Fuel pressure q Accelerator pedal: Depress to travel stop
(High idle) {kg/cm2} {1.5 to 3.0} {1.5 to 3.0}
Leakage of q Engine coolant temperature: 60 to 100 °C

pressure q Torque converter oil temperature: 60 to 80 °C ml/min Max. 10 Max. 10
limiter q With torque converter stalled
HD465-8, HD605-8 20-9


Engine SAA6D170E-7
Standard value
machine
Engine speed
Max. 960 Max. 960
q Engine coolant temperature: 60 1600 rpm
Fuel return to 100 °C 1700 rpm Max. 1020 Max. 1020
rate from q Torque converter oil temperature: ml/min
injector 60 to 80 °C 1800 rpm Max. 1080 Max. 1080
q With torque converter stalled 1900 rpm Max. 1140 Max. 1140
2000 rpm Max. 1200 Max. 1200
Lubrication system

Engine SAA6D170E-7
Standard value
machine
q Engine coolant temperature: 60
°C and above
q Engine oil (*1) Accelerator pedal:
Min. 0.34 Min. 0.21
EO10W30-LA Depress to travel stop
{Min. 3.47} {Min. 2.14}
EO15W45-LA (High idle)
EOS5W30-LA
Engine oil EOS5W40-LA MPa
pressure q Engine coolant temperature: 65 {kg/cm2}
°C and above
q Engine oil (*1)
Accelerator pedal: Not Min. 0.10 Min. 0.08
EO10W30-LA
depressed (Low idle) {Min. 1.02} {Min. 0.82}
EO15W45-LA
EOS5W30-LA
EOS5W40-LA
Engine oil
Full speed range (in oil pan) °C 90 to 110 Max. 120
temperature
*1: KES diesel engine oil
20-10 HD465-8, HD605-8

STANDARD VALUE TABLE FOR ENGINE: HD605-8

Performance

Engine SAA6D170E-7
Standard value
machine
Engine speed q Hydraulic oil temperature: 45 to 55 °C
rpm 2270±50 2270±50
at high idle q Torque converter oil temperature: 60 to 80 °C
q Engine coolant temperature: 65 AISS LOW switch: ON rpm 750±50 750±50
to 100 °C
Engine speed 55 °C
at low idle q Torque converter oil temperature: AISS LOW switch: rpm 1100±50 1100±50
60 to 80 °C OFF
q Accelerator pedal: Not depressed
(Low idle)
Air intake and exhaust system

Engine SAA6D170E-7
Standard value
machine
q Engine coolant temperature: 60 Min. 166 Min. 149
Gauge pressure
to 100 °C {Min. 1245} {Min. 1118}
q Torque converter oil temperature:
60 to 80 °C
Boost REMARK kPa
pressure q The gauge pressure does not in- {mmHg} Min. 267.3 Min. 250.3
Absolute pressure
clude atmospheric pressure. {Min. 2005} {Min. 1878}
q The absolute pressure is the sum
of the gauge pressure and atmo-
spheric pressure of 101.3 kPa
{760 mmHg} at sea level.
Exhaust
q Hydraulic oil temperature: 45 to 55 °C °C Max. 700 Max. 700
temperature
HD465-8, HD605-8 20-11


Engine SAA6D170E-7
Standard value
machine
q Engine cool- Accelerator pedal:
ant tempera- Measured at Depress to travel stop Max. 1.0 Max. 2.5
ture: 60 to measuring port of (High idle)
100 °C KDPF inlet piping With torque converter
q After it is kept Max. 1.5 Max. 2.5
Exhaust gas at normal stalled Bosch
color condition for 5 Accelerator pedal: index
seconds Depress to travel stop Max. 0.5 Max. 0.5
Torque con- Measured at
q (High idle)
verter oil tem- exhaust pipe
perature: 60 outlet With torque converter
Max. 0.5 Max. 0.5
to 80 °C stalled
Valve Engine coolant temperature: Normal Intake valve 0.32 -

mm
clearance temperature Exhaust valve 0.62 -
Accelerator pedal:
EGR valve oil Engine coolant temperature: 60 to Min. 1.80 Min. 1.80
Depress to travel stop
pressure, 100 °C MPa {Min. 18.4} {Min. 18.4}
(High idle)
VGT oil {kg/cm2}
pressure Engine coolant temperature: 65 to Accelerator pedal: Not Min. 1.18 Min. 1.18
100 °C depressed (Low idle) {Min. 12} {Min. 12}
Main body

Engine SAA6D170E-7
Standard value
machine
Compression q Engine oil temperature: 40 to 60 °C MPa Min. 2.94 Min. 2.1

pressure q At start (engine speed): 210 to 250 rpm (reference) {kg/cm2} {Min. 30} {Min. 21}

Blowby kPa Max. 3.43 Max. 9.41
pressure {mmH2O} {Max. 350} {Max. 960}
Fuel system

Engine SAA6D170E-7
Standard value
machine
q Engine coolant temperature: 60 to 100 °C MPa 0.15 to 0.3 0.15 to 0.3
Fuel pressure q Accelerator pedal: Depress to travel stop
(High idle) {kg/cm2} {1.5 to 3.0} {1.5 to 3.0}
Leakage of q Engine coolant temperature: 60 to 100 °C

pressure q Torque converter oil temperature: 60 to 80 °C ml/min Max. 10 Max. 10
limiter q With torque converter stalled
20-12 HD465-8, HD605-8


Engine SAA6D170E-7
Standard value
machine
Engine speed
Max. 960 Max. 960
q Engine coolant temperature: 60 1600 rpm
Fuel return to 100 °C 1700 rpm Max. 1020 Max. 1020
rate from q Torque converter oil temperature: ml/min
injector 60 to 80 °C 1800 rpm Max. 1080 Max. 1080
q With torque converter stalled 1900 rpm Max. 1140 Max. 1140
2000 rpm Max. 1200 Max. 1200
Lubrication system

Engine SAA6D170E-7
Standard value
machine
°C and above
q Engine oil (*1) Accelerator pedal:
Min. 0.34 Min. 0.21
EO10W30-LA Depress to travel stop
{Min. 3.47} {Min. 2.14}
EO15W45-LA (High idle)
EOS5W30-LA
Engine oil EOS5W40-LA MPa
pressure q Engine coolant temperature: 65 {kg/cm2}
°C and above
q Engine oil (*1)
Accelerator pedal: Not Min. 0.10 Min. 0.08
EO10W30-LA
depressed (Low idle) {Min. 1.02} {Min. 0.82}
EO15W45-LA
EOS5W30-LA
EOS5W40-LA
Engine oil
Full speed range (in oil pan) °C 90 to 110 Max. 120
temperature
HD465-8, HD605-8 20-13

STANDARD VALUE TABLE FOR MACHINE: HD465-8 20 STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR MACHINE

STANDARD VALUE TABLE FOR MACHINE: HD465-8
Engine speed

Engine SAA6D170E-7
Standard value
machine
Engine speed
with the q Engine coolant temperature: 60 to 100 °C
torque q Torque converter oil temperature: 70 to 80 °C rpm 1931±100 1931±100
converter at q Hydraulic oil temperature: 45 to 55 °C
stall
Engine speed at automatic transmission (partial delay mode)

Engine SAA6D170E-7
Standard value
machine
q Engine coolant temperature: 65 Gear speed: F1 to F2 2010±50 2010±50
to 100 °C
q Transmission oil temperature: 60 Gear speed: F2 to F3 1775±50 1775±50
to 80 °C Gear speed: F3 to F4
Upshift Gear speed: F4 to F5 rpm
55 °C
q Foot brake: OFF Gear speed: F5 to F6 1725±50 1725±50
q Accelerator pedal: OFF, other
than when depressing to travel
Gear speed: F6 to F7
stop
q Engine coolant temperature: 65 Gear speed: F7 to F6
to 100 °C
q Transmission oil temperature: 60 1175±35 1175±35
Downshift Gear speed: F4 to F3 rpm
55 °C
Gear speed: F2 to F1 1277±35 1277±35
stop
20-14 HD465-8, HD605-8

20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR MACHINE: HD465-8
Engine speed at automatic transmission (coast mode)

Engine SAA6D170E-7
Standard value
machine
q Transmission oil temperature: 60
Upshift rpm 2450±50 2450±50
q Hydraulic oil temperature: 45 to Gear speed: F4 to F5
55 °C
q Foot brake: OFF Gear speed: F5 to F6
q Accelerator pedal: OFF
Downshift rpm
55 °C
Gear speed: F2 to F1 1509±50 1509±50
Engine speed at automatic transmission (brake mode)

Engine SAA6D170E-7
Standard value
machine
Upshift rpm 2450±50 2450±50
55 °C
q Foot brake: ON Gear speed: F5 to F6
Downshift rpm 1550±50 1550±50
55 °C
HD465-8, HD605-8 20-15

Engine speed at automatic transmission (modes other than the previous)

REMARK
The measure of increase in speed is calculated from the number of rotations of the transmission output shaft.

Engine SAA6D170E-7
Standard value
machine
q Engine cool-
ant tempera- Gear speed: F2 to F3
ture: 65 to
Rate of speed Gear speed: F3 to F4
100 °C 2010±50 2010±50
q Transmission increase: small Gear speed: F4 to F5
oil tempera-
ture: 60 to 80 Gear speed: F5 to F6
°C Gear speed: F6 to F7
Upshift q Hydraulic oil rpm
temperature: Gear speed: F1 to F2 2010±50 2010±50
45 to 55 °C Gear speed: F2 to F3
q Foot brake:
OFF Rate of speed Gear speed: F3 to F4
q Accelerator increase: large Gear speed: F4 to F5 1890±50 1890±50
pedal: De-
press to travel Gear speed: F5 to F6
stop
q Engine cool- Gear speed: F6 to F5

ant tempera-
Rate of speed Gear speed: F5 to F4 1350±50 1350±50
ture: 65 to
100 °C increase: small Gear speed: F4 to F3
q Transmission
oil tempera- Gear speed: F3 to F2
ture: 60 to 80 Gear speed: F2 to F1 1277±35 1277±35
Downshift °C rpm
q Hydraulic oil Gear speed: F7 to F6
temperature: Gear speed: F6 to F5
45 to 55 °C
q Foot brake: Rate of speed Gear speed: F5 to F4 1350±50 1350±50
OFF increase: large Gear speed: F4 to F3
q Accelerator
pedal: OFF Gear speed: F3 to F2
Gear speed: F2 to F1 1277±35 1277±35
20-16 HD465-8, HD605-8

Engine speed at torque converter lockup actuation

Engine SAA6D170E-7
Standard value
machine
q Engine coolant temperature: 65 Gear speed: F1, F2 1300 to 1500 1300 to 1500
to 100 °C
Operated q Transmission oil temperature: 60
Gear speed: F3, F4, rpm
(ON) to 80 °C 1250 to 1500 1250 to 1500
q Hydraulic oil temperature: 45 to F5, F6, F7
55 °C
q Engine coolant temperature: 65 Gear speed: F1, F2 1100 1100
to 100 °C
Released q Transmission oil temperature: 60
(OFF) to 80 °C 1050 1050
55 °C
Engine speed at over run prevention

Engine SAA6D170E-7
Standard value
machine
Operation at Gear speed: F1, F2,
2300 2300
low speed q Engine coolant temperature: 65 F3, F4, F5, R
mode 1 to 100 °C
(ON) Gear speed: F6, F7 2400 2400
rpm
Cancelation at to 80 °C
low speed q Hydraulic oil temperature: 45 to Gear speed: F1, F2,
55 °C 2300 2300
mode 1 F3, F4, F5, F6, F7, R
(OFF)
Gear speed: F1, F2,
Operation at 2400 2400
q Engine coolant temperature: 65 F3, F4
low speed to 100 °C
mode 2 (ON) Gear speed: F5, F6,
q Transmission oil temperature: 60 2450 2450
F7, R rpm
to 80 °C
Cancelation at q Hydraulic oil temperature: 45 to
55 °C Gear speed: F1, F2,
low speed 2300 2300
F3, F4, F5, F6, F7, R
mode 2 (OFF)
Gear speed: F1, F2,
2600 2600
F7, R
Operation at q Engine coolant temperature: 65 Gear speed: F3 2560 2560

high-speed to 100 °C Gear speed: F4 2530 2530
mode (ON) q Transmission oil temperature: 60
Gear speed: F5 rpm 2510 2510
to 80 °C
q Hydraulic oil temperature: 45 to Gear speed: F6 2500 2500
55 °C
Cancelation at
Gear speed: F1, F2,
high-speed 2350 2350
F3, F4, F5, F6, F7, R
mode (OFF)
HD465-8, HD605-8 20-17

Low speed mode 1: The lever position of the gear shift, or the lower speed step of the maximum speed setting (optional), is
more than the machine speed step. And the accelerator pedal is not depressed.
more than the machine speed step. And the accelerator pedal is depressed.
High-speed mode: Other than low speed mode 1 or low speed mode 2
Engine speed of engine over run

Engine SAA6D170E-7
Standard value
machine
q Engine coolant temperature: 65 Low speed mode 1, 2 2400 2400
to 100 °C
Activation
to 80 °C rpm
(ON)
q Hydraulic oil temperature: 45 to High-speed mode 2550 2550
55 °C
q Gear speed: All
Released q Transmission oil temperature: 60 to 80 °C
rpm 2300 2300
(OFF) q Hydraulic oil temperature: 45 to 55 °C
q Gear speed: All
Lever and pedal

Engine SAA6D170E-7
Standard value
machine
Force
required to
q At the middle of the lever knob N Max. 29.4 Max. 29.4
operate the
q Between each position {kg} {Max. 3.0} {Max. 3.0}
gear shift
lever
Gear shift q At the middle of the lever knob
mm 24.5±1 24.5±2
lever travel q Between each position
Force
required to
N 5.88 to 9.8 2.94 to 14.7
operate the
{kg} {0.6 to 1.0} {0.3 to 1.5}
retarder
control lever Position 10 mm away from top of lever (position 167 mm
Travel of away from the lever pivot point)
retarder
control lever deg. 0 to 78 (+0/-2) 0 to 78 (+0/-4)
(Operational
range)
20-18 HD465-8, HD605-8


Engine SAA6D170E-7
Standard value
machine
HOLD position to Max. 29.4 Max. 29.4
RAISE position {Max. 3.0} {Max. 3.0}
RAISE position to Comes back Comes back
HOLD position smoothly smoothly
Force HOLD position to Max. 29.4 Max. 29.4

required to q Engine stopped FLOAT position N {Max. 3.0} {Max. 3.0}
operate the q Middle of the handle FLOAT position to {kg} Max. 29.4 Max. 29.4
dump lever HOLD position {Max. 3.0} {Max. 3.0}
LOWER position to Comes back Comes back
FLOAT position smoothly smoothly
FLOAT position to Max. 29.4 Max. 29.4
LOWER position {Max. 3.0} {Max. 3.0}
RAISE position to
23.5±1 23.5±1
HOLD position
Dump lever
HOLD position to
operation - deg. 10.5±1 10.5±1
FLOAT position
angle
LOWER position to
13.0±1 13.0±1
FLOAT position
Force When the brake pedal 29.4 (+9.8/-4.9) 29.4 (+9.8/-4.9)
required to is depressed {3.0 (+1.0/-0.5)} {3.0 (+1.0/-0.5)}
N
operate the
Position 150 mm away from pedal {kg} 58.8 (+4.9/-9.8) 58.8 (+4.9/-9.8)
accelerator Depress to travel stop
pedal pivot point {6.0 (+0.5/-1.0)} {6.0 (+0.5/-1.0)}
Accelerator Depressed from the

mm 45±5 45±5
pedal travel start to travel stop
Force
required to N 235±29.4 235±29.4
operate the {kg} {24±3.0} {24±3.0}
brake pedal Position 150 mm away from pedal pivot point
Brake pedal
mm 40±5 40±10
travel
Force
required to
N 294±29.4 294±29.4
operate the
{kg} {30±3.0} {30±3.0}
secondary
Secondary
brake pedal mm 46±5 46±10
travel
HD465-8, HD605-8 20-19

Power train oil pressure

Engine SAA6D170E-7
Standard value
machine
Main relief MPa
q Transmission oil temperature: 70 to 90 °C 3.53±0.20 3.53±0.20
pressure of
power train
q Gear shift lever: N position {kg/cm2} {36.0±2.0} {36.0±2.0}
q Engine speed: 2000 rpm (target value)
q Torque converter oil temperature: Engine speed: 2000 0.83±0.29 0.83±0.29
Main flow 60 to 100 °C rpm (target value) MPa {8.5±3.0} {8.5±3.0}
selector valve q Transmission oil temperature: 70
inlet pressure to 90 °C Accelerator pedal: Not {kg/cm2} 3.42±0.29 3.42±0.29
q Gear shift lever: N position depressed (Low idle) {34.9±3.0} {34.9±3.0}

Inlet pressure MPa
of the torque
converter
Outlet q Torque converter oil temperature: 60 to 100 °C
pressure of q Transmission oil temperature: 70 to 90 °C MPa 0.59±0.10 0.59±0.10
the torque q Gear shift lever: N position {kg/cm2} {6.0±1.0} {6.0±1.0}
converter q Engine speed: 2000 rpm (target value)
Torque
converter MPa
pressure for
the lockup
q Gear shift lever: L position {kg/cm2} {19.5±2.0} {19.5±2.0}
clutch
Operation
pressure of MPa
the
transmission L
q Gear shift lever: Position 2 {kg/cm2} {19.5±2.0} {19.5±2.0}
clutch
Operation
pressure of MPa
the
transmission
H clutch
Operation
pressure of MPa
the
transmission
1st clutch
Operation
pressure of MPa
the
transmission
2nd clutch
Operation
pressure of MPa
the
transmission
3rd clutch
20-20 HD465-8, HD605-8


Engine SAA6D170E-7
Standard value
machine
Operation
pressure of MPa
the
transmission
4th clutch
Operation
pressure of MPa
the
transmission
q Gear shift lever: R position {kg/cm2} {32.5±2.0} {32.5±2.0}
R clutch
Oil pressure q Torque converter oil temperature: 60 to 100 °C MPa 0.18±0.05 0.18±0.05
of the q Transmission oil temperature: 70 to 90 °C
transmission q Engine speed: 2000 rpm (target value) {kg/cm2} {1.8±0.5} {1.8±0.5}
Travel speed

Engine SAA6D170E-7
Standard value
machine
Gear speed:
11.5±5% 11.5±5%
F1
Gear speed:
16.0±5% 16.0±5%
F2
Gear speed:
21.5±5% 21.5±5%
F3
q When the standard tires are attached (resistant to travel:
Gear speed: 3.3%) 29.5±5% 29.5±5%
F4 q Condition of travel ground: Flat
km/h
Gear speed: q Engine coolant temperature: 65 to 100 °C
q Transmission oil temperature: 60 to 80 °C 39.0±5% 39.0±5%
F5
q Dump body: Empty
Gear speed:
52.5±10% 52.5±10%
F6
Gear speed:
70.0±10% 70.0±10%
F7
Gear speed:
12.0±5% 12.0±5%
R
HD465-8, HD605-8 20-21

Nitrogen gas pressure (charge pressure) in brake accumulator

Engine SAA6D170E-7
Standard value
machine
For front 10.7±0.34 10.7±0.34
wheel brake {109±3.5} {109±3.5}
For rear wheel MPa 6.2±0.20 6.2±0.20
brake Gas temperature (ambient temperature): 20±5 °C {63±2.0} {63±2.0}
{kg/cm2}
For parking
6.2±0.20 6.2±0.20
brake and
{63±2.0} {63±2.0}
retarder brake
*1: Since the nitrogen gas pressure in the accumulator gradually decreases while using, adjust it into the standard range at
2,000 hours or 1-year inspection. Regardless of if it is in the standard value or not, it is not "faulty". For how the nitrogen gas
pressure varies with ambient temperature, see "TEST AND PRESSURIZE BRAKE ACCUMULATOR WITH NITROGEN GAS".
Brake oil pressure

Engine SAA6D170E-7
Standard value
machine
Cut-in
pressure of 14.2(+0.49/-0.98) 14.2(+0.49/-0.98)
accumulator {145(+5/-10)} {145(+5/-10)}
charge valve q Hydraulic oil temperature: 45 to 55 °C MPa
Cut-out q Accelerator pedal: Depress to travel stop (High idle) {kg/cm2}
20.6 20.6
pressure of
(+0.98/-1.47) (+0.98/-1.47)
accumulator
{210 (+10/-15)} {210 (+10/-15)}
charge valve
Operation
pressure for MPa 17.6±1.2 17.6±1.2
the front {kg/cm2} {180±12} {180±12}
wheel brake
Operation
pressure for Actuating pressure in the 1st operation after charging the MPa 9.8±0.69 9.8±0.69
the rear wheel accumulator and stopping the engine {kg/cm2} {100±7} {100±7}
brake
Operation
the retarder {kg/cm2} {88.5±6.5} {88.5±6.5}
brake
Operation
(cancel) MPa 9.85 9.85
q Engine: Stopped
pressure for (+0.98/-0.49) (+0.98/-0.49)
the parking
q Parking brake switch: Travel position {kg/cm2} {100.5 (+10/-5)} {100.5 (+10/-5)}
brake
20-22 HD465-8, HD605-8

KTCS oil pressure

Engine SAA6D170E-7
Standard value
machine
KTCS MPa 8.7±0.64 8.7±0.64
operation When KTCS valve is set
pressure {kg/cm2} {88.5±6.5} {88.5±6.5}
Brake performance

Engine SAA6D170E-7
Standard value
machine
q Condition of travel ground: Flat (hard road surface)
q Dump body: Empty Machine does Machine does
Performance
q Brake pedal: Depress to travel stop not move at not move at
of the foot -
q Gear shift lever: Position D (Shift display shows F2) engine speed engine speed
brake
q Stall the torque converter with the engine at standard 1810 rpm. 1810 rpm.
speed
Performance
q Retarder control lever: Pull fully toward this side not move at not move at
of the retarder -
brake
speed
Performance
q Parking brake switch: Park (P) position not move at not move at
of the parking -
brake
speed
Performance q Dump body: Empty Machine does Machine does
of the q Secondary brake pedal: Depress to travel stop not move at not move at
-
secondary q Gear shift lever: Position D (Shift display shows F2) engine speed engine speed
brake q Stall the torque converter with the engine at standard 1670 rpm. 1670 rpm.
speed
q Tire air pressure: Specified pressure (see Operation and
Maintenance Manual.)
q Road surface: Flat and dried pavement of ascent of 11.5°
Function of
(20.3%)
the parking - Stop Stop
q For the measuring attitude, see fig. 1 and 2 of "MACHINE
brake control
SETTING AND PROCEDURE TO MEASURE PERFOR-
MANCE".
q Dump body: When loaded weight is 55 t
Wear of front Brake pad thickness from the present position to the wear
mm 19.5 3
brake pad limit
Must be in Must be in
Wear of rear q Brake pedal: Depress to travel stop
- range of disc range of disc
brake disc q Measure with disc wear gauge
wear gauge wear gauge
HD465-8, HD605-8 20-23


Engine SAA6D170E-7
Standard value
machine
q Flat and dried road Dump body: Empty 22.3 22.3
q Control initial speed: 32 km/h
Foot brake q In good condition for operation:
distance to Front: 17.6 MPa {180 kg/cm2} Dump body: When m
stop 29.0 29.0
Rear: 9.8 MPa {180 kg/cm2} loaded weight is 55 t
q Distance from signal point to stop
point
Secondary q Flat and dried road
brake q Control initial speed: 32 km/h
m 60.9 60.9
distance to q Distance from the start of brake apply to the stop point
stop q Dump body: When loaded weight is 55 t
stop 23.6 23.6
q Distance from the start of brake
apply to the stop point
Steering

Engine SAA6D170E-7
Standard value
machine
q Road surface: Flat and dried pavement road
q Accelerator pedal: Not depressed (Low idle)
Force
q Point to measure: The distance the steering wheel turns N 14.7 to 29.4 14.7 to 29.4
required to
q Gear shift lever: N position {kg} {1.5 to 3.0} {1.5 to 3.0}
operate
q Operating speed: 10 rpm
q Dump body: Empty
* If the steering operation is impossible, it is available at low
speed travel.
q Engine: Stopped
Play q Point to measure: The distance the steering wheel turns mm Max. 135 Max. 135
q Until the point where the tires start to move
q Steering cylinder left (right) travel stop - right (left) travel
Amount of
stop Rotation 3.5±0.3 3.5±0.3
rotation
Engine speed: 750
Max. 5.2 Max. 5.2
rpm (target value)
q Steering cylinder left (right) travel
Operating stop - right (left) travel stop Engine speed: 1500
Sec. Max. 3.6 Max. 3.6
time q Operating speed: 60 rpm rpm (target value)
q Dump body: Empty
Engine speed: 2000
Max. 3.6 Max. 3.6
rpm (target value)
20-24 HD465-8, HD605-8


Engine SAA6D170E-7
Standard value
machine
q Hydraulic oil temperature: 45 to 55 °C
Steering MPa
q Steering and hoist pump: Swash plate angle set to maxi- 20.6±0.98 20.6±0.98
circuit relief
pressure
mum (adjustment table) {kg/cm2} {210±10} {210±10}
Source
pressure for q Hydraulic oil temperature: 45 to 55 °C MPa 20.6±0.98 20.6±0.98
the orbitrol q Accelerator pedal: Depress to travel stop (High idle) {kg/cm2} {210±10} {210±10}
valve
Source
the steering q Accelerator pedal: Depress to travel stop (High idle) {kg/cm2} {210±10} {210±10}
cylinder
Suspension cylinder

Engine SAA6D170E-7
Standard value
machine
q Road surface: Flat Installed length (a) mm 255±10 255±20
q Engine: Stopped
q Dump body: Empty
q For installed length (a) and (b),
Front MPa
see fig. 3 of "MACHINE SETTING Internal cylinder 3.84±0.39 3.84±0.39
AND PROCEDURE TO MEA- pressure {kg/cm2} {39.2±4.0} {39.2±4.0}
SURE PERFORMANCE" in
STANDARD VALUE TABLE.
q Road surface: Flat Installed length (b) mm 204±10 204±20
q Engine: Stopped
q Dump body: Empty
Rear MPa
Dump

Engine SAA6D170E-7
Standard value
machine
Relief
q Hydraulic oil temperature: 45 to 55 °C MPa
pressure for 20.6±0.98 20.6±0.98
q Dump lever: RAISE
the hoist
q Accelerator pedal: Depress to travel stop (High idle) {kg/cm2} {210±10} {210±10}
circuit
HD465-8, HD605-8 20-25


Engine SAA6D170E-7
Standard value
machine
Source
pressure for 20.6±0.98 20.6±0.98
q Dump lever: RAISE
the hoist
cylinder
Source
the hoist EPC q Accelerator pedal: Depress to travel stop (High idle) {kg/cm2} {35±2} {35±2}
valve
2.83±0.15 2.83±0.15
Dump lever: RAISE
{28.9±1.5} {28.9±1.5}
Outlet q Hydraulic oil temperature: 45 to
pressure for 55 °C MPa 1.47±0.15 1.47±0.15
Dump lever: FLOAT
the hoist EPC q Accelerator pedal: Depress to {kg/cm2} {15.0±1.5} {15.0±1.5}
valve travel stop (High idle)
3.05±0.15 3.05±0.15
Dump lever: LOWER
{31.1±1.5} {31.1±1.5}
q Hydraulic oil temperature: 80±5 °C
Dump body
q Dump lever: RAISE Sec. 11.5±1.5 11.5±1.5
raise time
Dump body
q Dump lever: FLOAT Sec. 11.5±1.5 11.5±1.5
lower time
The distance No. 2 cylinder rod retracts five minutes after the
Hydraulic drift engine is stopped when No. 2 cylinder (rod) is extended mm Max. 85 Max. 170
about 100 mm
Dump body Hoist cylinder: Raised travel stop 4.00 to 4.70 4.00 to 4.70
position Hoist cylinder: Lowered travel stop (When dump body is V
sensor 0.46 to 0.54 0.46 to 0.54
seated)
Radiator fan

Engine SAA6D170E-7
Standard value
machine
Fan speed rpm 1300±50 1300±50
q Setting of fan mode: Max.
Fan drive q Hydraulic oil temperature: 45 to 55 °C MPa

15.9±2.5 15.9±2.5
pressure q Setting of fan mode: Max. {kg/cm2}
20-26 HD465-8, HD605-8

STANDARD VALUE TABLE FOR MACHINE: HD605-8

Engine speed

Engine SAA6D170E-7
Standard value
machine
Engine speed
with the q Engine coolant temperature: 60 to 100 °C
torque q Torque converter oil temperature: 70 to 80 °C rpm 1931±100 1931±100
converter at q Hydraulic oil temperature: 45 to 55 °C
stall
Engine speed at automatic transmission (partial delay mode)

Engine SAA6D170E-7
Standard value
machine
q Engine coolant temperature: 65 Gear speed: F1 to F2 2010±50 2010±50
to 100 °C
q Transmission oil temperature: 60 Gear speed: F2 to F3 1775±50 1775±50
Upshift Gear speed: F4 to F5 rpm
55 °C
stop
q Engine coolant temperature: 65 Gear speed: F7 to F6
to 100 °C
q Transmission oil temperature: 60 Gear speed: F6 to F5
1175±35 1175±35
Downshift Gear speed: F4 to F3 rpm
55 °C
Gear speed: F2 to F1 1277±35 1277±35
stop
HD465-8, HD605-8 20-27

Engine speed at automatic transmission (coast mode)

Engine SAA6D170E-7
Standard value
machine
Upshift rpm 2450±50 2450±50
55 °C
q Foot brake: OFF Gear speed: F5 to F6
Downshift rpm
55 °C
Gear speed: F2 to F1 1509±50 1509±50
Engine speed at automatic transmission (brake mode)

Engine SAA6D170E-7
Standard value
machine
Upshift rpm 2450±50 2450±50
55 °C
Downshift rpm 1550±50 1550±50
55 °C
20-28 HD465-8, HD605-8

Engine speed at automatic transmission (modes other than the previous)

REMARK
The measure of increase in speed is calculated from the number of rotations of the transmission output shaft.

Engine SAA6D170E-7
Standard value
machine
q Engine cool-
ant tempera- Gear speed: F2 to F3
ture: 65 to
Rate of speed Gear speed: F3 to F4
100 °C 2010±50 2010±50
q Transmission increase: small Gear speed: F4 to F5
oil tempera-
ture: 60 to 80 Gear speed: F5 to F6
°C Gear speed: F6 to F7
Upshift q Hydraulic oil rpm
temperature: Gear speed: F1 to F2 2010±50 2010±50
45 to 55 °C Gear speed: F2 to F3
q Foot brake:
OFF Rate of speed Gear speed: F3 to F4
q Accelerator increase: large Gear speed: F4 to F5 1890±50 1890±50
pedal: De-
press to travel Gear speed: F5 to F6
stop
q Engine cool- Gear speed: F6 to F5

ant tempera-
Rate of speed Gear speed: F5 to F4 1350±50 1350±50
ture: 65 to
100 °C increase: small Gear speed: F4 to F3
q Transmission
oil tempera- Gear speed: F3 to F2
ture: 60 to 80 Gear speed: F2 to F1 1277±35 1277±35
Downshift °C rpm
q Hydraulic oil Gear speed: F7 to F6
temperature: Gear speed: F6 to F5
45 to 55 °C
q Foot brake: Rate of speed Gear speed: F5 to F4 1350±50 1350±50
OFF increase: large Gear speed: F4 to F3
q Accelerator
pedal: OFF Gear speed: F3 to F2
Gear speed: F2 to F1 1277±35 1277±35
HD465-8, HD605-8 20-29

Engine speed at torque converter lockup actuation

Engine SAA6D170E-7
Standard value
machine
q Engine coolant temperature: 65 Gear speed: F1, F2 1300 to 1500 1300 to 1500
to 100 °C
Operated q Transmission oil temperature: 60
(ON) to 80 °C 1250 to 1500 1250 to 1500
55 °C
q Engine coolant temperature: 65 Gear speed: F1, F2 1100 1100
to 100 °C
Released q Transmission oil temperature: 60
(OFF) to 80 °C 1050 1050
55 °C
Engine speed at over run prevention

Engine SAA6D170E-7
Standard value
machine
Operation at Gear speed: F1, F2,
2300 2300
low speed q Engine coolant temperature: 65 F3, F4, F5, R
mode 1 to 100 °C
(ON) Gear speed: F6, F7 2400 2400
rpm
Cancelation at to 80 °C
low speed q Hydraulic oil temperature: 45 to Gear speed: F1, F2,
55 °C 2300 2300
mode 1 F3, F4, F5, F6, F7, R
(OFF)
Gear speed: F1, F2,
Operation at 2400 2400
q Engine coolant temperature: 65 F3, F4
low speed to 100 °C
mode 2 (ON) Gear speed: F5, F6,
q Transmission oil temperature: 60 2450 2450
F7, R rpm
to 80 °C
Cancelation at q Hydraulic oil temperature: 45 to
55 °C Gear speed: F1, F2,
low speed 2300 2300
F3, F4, F5, F6, F7, R
mode 2 (OFF)
Gear speed: F1, F2,
2600 2600
F7, R
Operation at q Engine coolant temperature: 65 Gear speed: F3 2560 2560

high-speed to 100 °C Gear speed: F4 2530 2530
mode (ON) q Transmission oil temperature: 60
Gear speed: F5 rpm 2510 2510
to 80 °C
q Hydraulic oil temperature: 45 to Gear speed: F6 2500 2500
55 °C
Cancelation at
Gear speed: F1, F2,
high-speed 2350 2350
F3, F4, F5, F6, F7, R
mode (OFF)
20-30 HD465-8, HD605-8

Engine speed of engine over run

Engine SAA6D170E-7
Standard value
machine
q Engine coolant temperature: 65 Low speed mode 1, 2 2400 2400
to 100 °C
Activation
to 80 °C rpm
(ON)
q Hydraulic oil temperature: 45 to High-speed mode 2550 2550
55 °C
q Gear speed: All
Released q Transmission oil temperature: 60 to 80 °C
rpm 2300 2300
(OFF) q Hydraulic oil temperature: 45 to 55 °C
q Gear speed: All
Lever and pedal

Engine SAA6D170E-7
Standard value
machine
Force
required to
q At the middle of the lever knob N Max. 29.4 Max. 29.4
operate the
q Between each position {kg} {Max. 3.0} {Max. 3.0}
gear shift
lever
Gear shift q At the middle of the lever knob
mm 24.5±1 24.5±2
lever travel q Between each position
Force
required to
N 5.88 to 9.8 2.94 to 14.7
operate the
{kg} {0.6 to 1.0} {0.3 to 1.5}
retarder
control lever Position 10 mm away from top of lever (position 167 mm
Travel of away from the lever pivot point)
retarder
control lever deg. 0 to 78 (+0/-2) 0 to 78 (+0/-4)
(Operational
range)
HD465-8, HD605-8 20-31


Engine SAA6D170E-7
Standard value
machine
HOLD position to Max. 29.4 Max. 29.4
RAISE position {Max. 3.0} {Max. 3.0}
RAISE position to Comes back Comes back
HOLD position smoothly smoothly
Force HOLD position to Max. 29.4 Max. 29.4

required to q Engine stopped FLOAT position N {Max. 3.0} {Max. 3.0}
operate the q Middle of the handle FLOAT position to {kg} Max. 29.4 Max. 29.4
dump lever HOLD position {Max. 3.0} {Max. 3.0}
LOWER position to Comes back Comes back
FLOAT position smoothly smoothly
FLOAT position to Max. 29.4 Max. 29.4
LOWER position {Max. 3.0} {Max. 3.0}
RAISE position to
23.5±1 23.5±1
HOLD position
Dump lever
HOLD position to
operation - deg. 10.5±1 10.5±1
FLOAT position
angle
LOWER position to
13.0±1 13.0±1
FLOAT position
Force When the brake pedal 29.4 (+9.8/-4.9) 29.4 (+9.8/-4.9)
required to is depressed {3.0 (+1.0/-0.5)} {3.0 (+1.0/-0.5)}
N
operate the
Position 150 mm away from pedal {kg} 58.8 (+4.9/-9.8) 58.8 (+4.9/-9.8)
accelerator Depress to travel stop
pedal pivot point {6.0 (+0.5/-1.0)} {6.0 (+0.5/-1.0)}
Accelerator Depressed from the

mm 45±5 45±5
pedal travel start to travel stop
Force
required to N 235±29.4 235±29.4
operate the {kg} {24±3.0} {24±3.0}
Brake pedal
mm 40±5 40±10
travel
Force
required to
N 294±29.4 294±29.4
operate the
{kg} {30±3.0} {30±3.0}
secondary
Secondary
brake pedal mm 46±5 46±10
travel
20-32 HD465-8, HD605-8

Power train oil pressure

Engine SAA6D170E-7
Standard value
machine
Main relief MPa
pressure of
power train
q Torque converter oil temperature: Engine speed: 2000 0.83±0.29 0.83±0.29
Main flow 60 to 100 °C rpm (target value) MPa {8.5±3.0} {8.5±3.0}
selector valve q Transmission oil temperature: 70
inlet pressure to 90 °C Accelerator pedal: Not {kg/cm2} 3.42±0.29 3.42±0.29
q Gear shift lever: N position depressed (Low idle) {34.9±3.0} {34.9±3.0}

Inlet pressure MPa
of the torque
converter
Outlet q Torque converter oil temperature: 60 to 100 °C
pressure of q Transmission oil temperature: 70 to 90 °C MPa 0.59±0.10 0.59±0.10
the torque q Gear shift lever: N position {kg/cm2} {6.0±1.0} {6.0±1.0}
converter q Engine speed: 2000 rpm (target value)
Torque
converter MPa
pressure for
the lockup
clutch
Operation
pressure of MPa
the
transmission L
clutch
Operation
pressure of MPa
the
transmission
H clutch
Operation
pressure of MPa
the
transmission
1st clutch
Operation
pressure of MPa
the
transmission
2nd clutch
Operation
pressure of MPa
the
transmission
3rd clutch
HD465-8, HD605-8 20-33


Engine SAA6D170E-7
Standard value
machine
Operation
pressure of MPa
the
transmission
4th clutch
Operation
pressure of MPa
the
transmission
q Gear shift lever: R position {kg/cm2} {32.5±2.0} {32.5±2.0}
R clutch
Oil pressure q Torque converter oil temperature: 60 to 100 °C MPa 0.18±0.05 0.18±0.05
of the q Transmission oil temperature: 70 to 90 °C
transmission q Engine speed: 2000 rpm (target value) {kg/cm2} {1.8±0.5} {1.8±0.5}
Travel speed

Engine SAA6D170E-7
Standard value
machine
Gear speed:
11.5±5% 11.5±5%
F1
Gear speed:
16.0±5% 16.0±5%
F2
Gear speed:
21.5±5% 21.5±5%
F3
q When the standard tires are attached (resistant to travel:
Gear speed: 3.3%) 29.5±5% 29.5±5%
F4 q Condition of travel ground: Flat
km/h
Gear speed: q Engine coolant temperature: 65 to 100 °C
q Transmission oil temperature: 60 to 80 °C 39.0±5% 39.0±5%
F5
q Dump body: Empty
Gear speed:
52.5±10% 52.5±10%
F6
Gear speed:
70.0±10% 70.0±10%
F7
Gear speed:
12.0±5% 12.0±5%
R
20-34 HD465-8, HD605-8

Nitrogen gas pressure (charge pressure) in brake accumulator

Engine SAA6D170E-7
Standard value
machine
For front 10.7±0.34 10.7±0.34
wheel brake {109±3.5} {109±3.5}
For rear wheel MPa 6.2±0.20 6.2±0.20
brake Gas temperature (ambient temperature): 20±5 °C {63±2.0} {63±2.0}
{kg/cm2}
For parking
6.2±0.20 6.2±0.20
brake and
{63±2.0} {63±2.0}
retarder brake
*1: Since the nitrogen gas pressure in the accumulator gradually decreases while using, adjust it into the standard range at
2,000 hours or 1-year inspection. Regardless of if it is in the standard value or not, it is not "faulty". For how the nitrogen gas
pressure varies with ambient temperature, see "TEST AND PRESSURIZE BRAKE ACCUMULATOR WITH NITROGEN GAS".
Brake oil pressure

Engine SAA6D170E-7
Standard value
machine
Cut-in
pressure of 14.2(+0.49/-0.98) 14.2(+0.49/-0.98)
accumulator {145(+5/-10)} {145(+5/-10)}
charge valve q Hydraulic oil temperature: 45 to 55 °C MPa
Cut-out q Accelerator pedal: Depress to travel stop (High idle) {kg/cm2}
20.6 20.6
pressure of
(+0.98/-1.47) (+0.98/-1.47)
accumulator
{210 (+10/-15)} {210 (+10/-15)}
charge valve
Operation
the front {kg/cm2} {180±12} {180±12}
wheel brake
Operation
pressure for Actuating pressure in the 1st operation after charging the MPa 9.8±0.69 9.8±0.69
the rear wheel accumulator and stopping the engine {kg/cm2} {100±7} {100±7}
brake
Operation
the retarder {kg/cm2} {88.5±6.5} {88.5±6.5}
brake
Operation
(cancel) MPa 9.85 9.85
q Engine: Stopped
pressure for (+0.98/-0.49) (+0.98/-0.49)
the parking
q Parking brake switch: Travel position {kg/cm2} {100.5 (+10/-5)} {100.5 (+10/-5)}
brake
HD465-8, HD605-8 20-35

KTCS oil pressure

Engine SAA6D170E-7
Standard value
machine
KTCS MPa 8.7±0.64 8.7±0.64
operation When KTCS valve is set
pressure {kg/cm2} {88.5±6.5} {88.5±6.5}
Brake performance

Engine SAA6D170E-7
Standard value
machine
Performance
q Brake pedal: Depress to travel stop not move at not move at
of the foot -
brake
speed
Performance
q Retarder control lever: Pull fully toward this side not move at not move at
of the retarder -
brake
speed
Performance
q Parking brake switch: Park (P) position not move at not move at
of the parking -
brake
speed
Performance q Dump body: Empty Machine does Machine does
of the q Secondary brake pedal: Depress to travel stop not move at not move at
-
secondary q Gear shift lever: Position D (Shift display shows F2) engine speed engine speed
brake q Stall the torque converter with the engine at standard 1670 rpm. 1670 rpm.
speed
q Road surface: Flat and dried pavement of ascent of 11.5°
Function of
(20.3%)
the parking - Stop Stop
q For the measuring attitude, see fig. 1 and 2 of "MACHINE
brake control
SETTING AND PROCEDURE TO MEASURE PERFOR-
MANCE".
q Dump body: When loaded weight is 63 t
Wear of front Brake pad thickness from the present position to the wear
mm 19.5 3
brake pad limit
Must be in Must be in
Wear of rear q Brake pedal: Depress to travel stop
- range of disc range of disc
brake disc q Measure with disc wear gauge
wear gauge wear gauge
20-36 HD465-8, HD605-8


Engine SAA6D170E-7
Standard value
machine
stop 29.0 29.0
q Distance from signal point to stop
point
Secondary q Flat and dried road
brake q Control initial speed: 32 km/h
m 60.9 60.9
distance to q Distance from the start of brake apply to the stop point
stop q Dump body: When loaded weight is 63 t
stop 23.6 23.6
q Distance from the start of brake
apply to the stop point
Steering

Engine SAA6D170E-7
Standard value
machine
q Road surface: Flat and dried pavement road
Force
q Point to measure: The distance the steering wheel turns N 14.7 to 29.4 14.7 to 29.4
required to
q Gear shift lever: N position {kg} {1.5 to 3.0} {1.5 to 3.0}
operate
q Operating speed: 10 rpm
q Dump body: Empty
* If the steering operation is impossible, it is available at low
speed travel.
q Engine: Stopped
Play q Point to measure: The distance the steering wheel turns mm Max. 135 Max. 135
q Until the point where the tires start to move
q Steering cylinder left (right) travel stop - right (left) travel
Amount of
stop Rotation 3.5±0.3 3.5±0.3
rotation
Engine speed: 750
Max. 5.2 Max. 5.2
rpm (target value)
q Steering cylinder left (right) travel
Operating stop - right (left) travel stop Engine speed: 1500
time q Operating speed: 60 rpm rpm (target value)
q Dump body: Empty
Engine speed: 2000
Max. 3.6 Max. 3.6
rpm (target value)
HD465-8, HD605-8 20-37


Engine SAA6D170E-7
Standard value
machine
Steering MPa
q Steering and hoist pump: Swash plate angle set to maxi- 20.6±0.98 20.6±0.98
circuit relief
pressure
mum (adjustment table) {kg/cm2} {210±10} {210±10}
Source
the orbitrol q Accelerator pedal: Depress to travel stop (High idle) {kg/cm2} {210±10} {210±10}
valve
Source
the steering q Accelerator pedal: Depress to travel stop (High idle) {kg/cm2} {210±10} {210±10}
cylinder
Suspension cylinder

Engine SAA6D170E-7
Standard value
machine
q Road surface: Flat Installed length (a) mm 255±10 255±20
q Engine: Stopped
q Dump body: Empty
Front MPa
q Road surface: Flat Installed length (b) mm 204±10 204±20
q Engine: Stopped
q Dump body: Empty
Rear MPa
Dump

Engine SAA6D170E-7
Standard value
machine
Relief
pressure for 20.6±0.98 20.6±0.98
q Dump lever: RAISE
the hoist
circuit
20-38 HD465-8, HD605-8


Engine SAA6D170E-7
Standard value
machine
Source
pressure for 20.6±0.98 20.6±0.98
q Dump lever: RAISE
the hoist
cylinder
Source
the hoist EPC q Accelerator pedal: Depress to travel stop (High idle) {kg/cm2} {35±2} {35±2}
valve
2.83±0.15 2.83±0.15
Dump lever: RAISE
{28.9±1.5} {28.9±1.5}
Outlet q Hydraulic oil temperature: 45 to
pressure for 55 °C MPa 1.47±0.15 1.47±0.15
Dump lever: FLOAT
the hoist EPC q Accelerator pedal: Depress to {kg/cm2} {15.0±1.5} {15.0±1.5}
valve travel stop (High idle)
3.05±0.15 3.05±0.15
Dump lever: LOWER
{31.1±1.5} {31.1±1.5}
Dump body
q Dump lever: RAISE Sec. 11.5±1.5 11.5±1.5
raise time
Dump body
q Dump lever: FLOAT Sec. 11.5±1.5 11.5±1.5
lower time
The distance No. 2 cylinder rod retracts five minutes after the
Hydraulic drift engine is stopped when No. 2 cylinder (rod) is extended mm Max. 85 Max. 170
about 100 mm
Dump body Hoist cylinder: Raised travel stop 4.00 to 4.70 4.00 to 4.70
position Hoist cylinder: Lowered travel stop (When dump body is V
sensor 0.46 to 0.54 0.46 to 0.54
seated)
Radiator fan

Engine SAA6D170E-7
Standard value
machine
Fan speed rpm 1300±50 1300±50
q Setting of fan mode: Max.
Fan drive q Hydraulic oil temperature: 45 to 55 °C MPa

15.9±2.5 15.9±2.5
pressure q Setting of fan mode: Max. {kg/cm2}
HD465-8, HD605-8 20-39

MACHINE SETTING AND PROCEDURE TO MEASURE PERFORMANCE 20 STANDARD VALUE TABLE
MACHINE SETTING AND PROCEDURE TO MEASURE PERFOR-

MANCE
Fig. 1
Fig. 2
Fig. 3
20-40 HD465-8, HD605-8

30 TEST AND ADJUST
HD465-8, HD605-8 30-1

CONTENTS 30 TEST AND ADJUST
CONTENTS
ABBREVIATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-6
RELATED INFORMATION TO TEST AND ADJUST- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-11
TOOLS TO TEST AND ADJUST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-11
DIAGRAM FOR TEST AND ADJUST TOOLS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-21
TEST ENGINE SPEED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-22
PROCEDURE TO TEST ENGINE SPEED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-22
TEST BOOST PRESSURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-24
BOOST PRESSURE TEST BY MACHINE MONITOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-24
PROCEDURE TO TEST BOOST PRESSURE WITH TEST TOOLS - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-26
TESTING EXHAUST GAS TEMPERATURE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-28
EXHAUST GAS TEMPERATURE TEST BY THE MACHINE MONITOR - - - - - - - - - - - - - - - - - - - - - - - - - 30-28
PROCEDURE TO TEST EXHAUST GAS TEMPERATURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-30
TEST EXHAUST GAS COLOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-32
TEST EXHAUST GAS COLOR WITH THE HANDY SMOKE CHECKER - - - - - - - - - - - - - - - - - - - - - - - - - 30-32
TEST EXHAUST GAS COLOR WITH SMOKE METER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-33
TEST AND ADJUST VALVE CLEARANCE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-35
TEST VALVE CLEARANCE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-35
ADJUST VALVE CLEARANCE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-36
COMPRESSION TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-38
COMPRESSION PRESSURE TEST- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-38
BLOWBY PRESSURE TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-42
BLOWBY PRESSURE TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-42
TEST ENGINE OIL PRESSURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-44
ENGINE OIL PRESSURE TEST BY MACHINE MONITOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-44
TEST ENGINE OIL PRESSURE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-44
EGR VALVE AND VGT OIL PRESSURE TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-46
EGR VALVE AND VGT OIL PRESSURE TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-46
FUEL PRESSURE TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-47
FUEL PRESSURE TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-47
FUEL RETURN RATE AND LEAKAGE TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-49
FUEL RETURN RATE AND LEAKAGE TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-50
BLEEDING AIR FROM FUEL SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-53
BLEED AIR FROM FUEL SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-53
FUEL CIRCUIT LEAK TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-55
FUEL CIRCUIT LEAK TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-55
SUPPLY PUMP TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-57
SUPPLY PUMP TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-57
CYLINDER CUT-OUT MODE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-60
NO-INJECTION CRANKING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-61
CLEAN FUEL DOSER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-62
CLEAN FUEL DOSER- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-62
PROGRAM INJECTOR TRIM CODE VALUE TO ENGINE CONTROLLER - - - - - - - - - - - - - - - - - - - - - - - - - - 30-64
PROCEDURE TO PROGRAM INJECTOR TRIM CODE VALUE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-64
PROGRAM ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER - - - - - - - - - - - - - - 30-70
PROCEDURE TO PROGRAM SOOT ASH ACCUMULATION CORRECTION TO ENGINE CONTROLLER
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-70
TEST TORQUE CONVERTER STALL SPEED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-71
TEST TORQUE CONVERTER STALL SPEED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-71
30-2 HD465-8, HD605-8

30 TEST AND ADJUST CONTENTS
RADIATOR FAN SPEED TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-73

RADIATOR FAN SPEED TEST- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-73
POWER TRAIN - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-75
TEST POWER TRAIN OIL PRESSURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-75
POWER TRAIN OIL PRESSURE TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-78
ADJUST TRANSMISSION INPUT SHAFT SPEED SENSOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-90
ADJUST TRANSMISSION INPUT SPEED SENSOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-90
ADJUST TRANSMISSION INTERMEDIATE SPEED SENSOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-91
ADJUST THE TRANSMISSION INTERMEDIATE SPEED SENSOR - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-91
ADJUST TRANSMISSION OUTPUT SPEED SENSOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-92
ADJUST TRANSMISSION OUTPUT SPEED SENSOR- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-92
CHECK AFTER ADJUSTMENT OF TRANSMISSION SPEED SENSORS - - - - - - - - - - - - - - - - - - - - - - - - - - 30-93
PROCEDURE TO CHECK AFTER ADJUSTMENT THE TRANSMISSION SPEED SENSORS - - - - - - - - - 30-93
MOVE A MACHINE WITH ELECTRICAL SYSTEM PROBLEMS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-94
MOVE A MACHINE WITH ENGINE CONTROL SYSTEM PROBLEMS- - - - - - - - - - - - - - - - - - - - - - - - - - 30-94
PROCEDURE TO MOVE MACHINE WITH TRANSMISSION CONTROL SYSTEM PROBLEM - - - - - - - - 30-94
STEERING SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-99
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-99
TEST STEERING CIRCUIT OIL PRESSURE WITH THE MACHINE MONITOR - - - - - - - - - - - - - - - - - - - 30-99
TEST STEERING CIRCUIT PRESSURE WITH TEST TOOLS- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-99
PROCEDURE FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE - - - - - - - - - - - - - - - - - - - - - - - - 30-101
TEST SUPPLY PRESSURE OF ORBITROL VALVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-102
PROCEDURE TO TEST SUPPLY PRESSURE OF ORBITROL VALVE - - - - - - - - - - - - - - - - - - - - - - - - - 30-102
TEST STEERING CYLINDER PRESSURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-104
PROCEDURE TO TEST STEERING CYLINDER PRESSURE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-104
BLEED AIR FROM STEERING CYLINDER CIRCUIT- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-106
PROCEDURE TO BLEED AIR FROM STEERING CYLINDER CIRCUIT - - - - - - - - - - - - - - - - - - - - - - - - 30-106
BRAKE SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-107
RELEASE PRESSURE IN BRAKE ACCUMULATOR CIRCUIT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-107
RELEASE THE PRESSURE IN BRAKE ACCUMULATOR CIRCUIT - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-107
TEST WHEEL BRAKE OIL PRESSURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-108
FRONT BRAKE ACTUATION PRESSURE TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-108
REAR BRAKE ACTUATION PRESSURE TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-109
RETARDER BRAKE PRESSURE TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-110
RETARDER BRAKE ACTUATION PRESSURE TEST (FOR MACHINE WITH KTCS) - - - - - - - - - - - - - - - 30-111
TEST AND ADJUST BRAKE ACCUMULATOR PRESSURE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-112
MEASURE BRAKE ACCUMULATOR PRESSURE USING THE MONITOR - - - - - - - - - - - - - - - - - - - - - - 30-112
TEST BRAKE ACCUMULATOR PRESSURE WITH TEST TOOLS - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-112
ADJUST BRAKE ACCUMULATOR PRESSURE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-114
TEST NITROGEN GAS PRESSURE IN BRAKE ACCUMULATOR AND CHARGE NITROGEN GAS - - - - - - - 30-115
TEST NITROGEN GAS PRESSURE IN BRAKE ACCUMULATOR(FRONT) - - - - - - - - - - - - - - - - - - - - - - 30-116
TEST NITROGEN GAS PRESSURE IN BRAKE ACCUMULATOR (REAR BRAKE AND PARKING BRAKE)
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-120
METHOD FOR CHARGING NITROGEN GAS IN BRAKE ACCUMULATOR - - - - - - - - - - - - - - - - - - - - - - 30-124
METHOD FOR DISCHARGING THE NITROGEN GAS WHEN DISPOSING OF THE ACCUMULATOR - - 30-130
TEST BRAKE PERFORMANCE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-131
TEST FOOT BRAKE PERFORMANCE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-131
PROCEDURE TO TEST RETARDER BRAKE PERFORMANCE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-132
PROCEDURE TO TEST PARKING BRAKE PERFORMANCE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-133
BLEED AIR FROM BRAKE CIRCUIT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-134
PROCEDURE TO BLEED AIR FROM FRONT BRAKE CIRCUIT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-134
HD465-8, HD605-8 30-3

CONTENTS 30 TEST AND ADJUST
PROCEDURE TO BLEED AIR FROM FRONT BRAKE CIRCUIT (FOR MACHINE WITH ABS) - - - - - - - - - 30-135
PROCEDURE TO BLEED AIR FROM REAR BRAKE CIRCUIT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-136
PROCEDURE TO BLEED AIR FROM REAR BRAKE CIRCUIT (FOR MACHINE WITH ABS/WITHOUT KTCS)
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-138
PROCEDURE TO BLEED AIR FROM REAR BRAKE CIRCUIT (FOR MACHINE WITH KTCS) - - - - - - - - - 30-140
PROCEDURE TO BLEED AIR FROM REAR BRAKE CIRCUIT (FOR MACHINE WITH ABS/KTCS) - - - - - 30-142
PROCEDURE TO BLEED AIR FROM PARKING BRAKE CIRCUIT- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-144
TEST PARKING BRAKE OIL PRESSURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-146
PROCEDURE TO TEST PARKING BRAKE OIL PRESSURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-146
RELEASE PARKING BRAKE MANUALLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-147
PROCEDURE TO RELEASE THE PARKING BRAKE MANUALLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-147
TEST THE AMOUNT OF FRONT BRAKE PAD WEAR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-148
PROCEDURE TO VISUALLY TEST THE AMOUNT OF FRONT BRAKE PAD WEAR- - - - - - - - - - - - - - - - 30-148
PROCEDURE TO TEST FRONT BRAKE PAD WEAR WITH GAUGE MEASURE - - - - - - - - - - - - - - - - - - 30-148
TEST THE QUANTITY OF REAR BRAKE DISC WEAR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-149
PROCEDURE TO TEST THE QUANTITY OF REAR BRAKE DISC WEAR - - - - - - - - - - - - - - - - - - - - - - - 30-149
HYDRAULIC SYSTEM- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-150
TEST AND ADJUST HOIST CIRCUIT OIL PRESSURE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-150
PROCEDURE TO TEST HOIST CIRCUIT OIL PRESSURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-150
PROCEDURE TO ADJUST HOIST CIRCUIT OIL PRESSURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-151
TEST HOIST CYLINDER SUPPLY PRESSURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-152
PROCEDURE TO TEST HOIST CYLINDER SUPPLY PRESSURE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-152
TEST OIL PRESSURE OF HOIST EPC VALVE CIRCUIT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-154
PROCEDURE TO TEST HOIST EPC VALVE SUPPLY PRESSURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-154
PROCEDURE TO TEST HOIST EPC VALVE OUTLET PRESSURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-155
TEST RADIATOR FAN CIRCUIT OIL PRESSURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-156
PROCEDURE TO TEST RADIATOR FAN CIRCUIT OIL PRESSURE - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-156
TEST AND ADJUST FRONT SUSPENSION CYLINDER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-158
PROCEDURE TO TEST FRONT SUSPENSION CYLINDER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-158
PROCEDURE TO ADJUST FRONT SUSPENSION CYLINDER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-159
TEST AND ADJUST FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION) - - - 30-163
PROCEDURE TO TEST FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION)
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-163
PROCEDURE FOR ADJUSTING FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION
SPECIFICATION) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-164
TEST AND ADJUST REAR SUSPENSION CYLINDER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-165
PROCEDURE TO TEST REAR SUSPENSION CYLINDER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-165
PROCEDURE TO ADJUST REAR SUSPENSION CYLINDER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-166
TEST KTCS CIRCUIT OIL PRESSURE (FOR MACHINE WITH KTCS) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-170
PROCEDURE TO TEST THE OIL PRESSURE OF KTCS CIRCUIT WITH TEST TOOLS - - - - - - - - - - - - - 30-170
PROCEDURE TO TEST THE OIL PRESSURE OF KTCS CIRCUIT WITH TEST TOOLS - - - - - - - - - - - - - 30-170
WORK EQUIPMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-172
TEST AND ADJUST DUMP BODY POSITIONER SENSOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-172
PROCEDURE TO TEST THE BODY POSITION SENSOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-172
PROCEDURE TO ADJUST DUMP BODY POSITION SENSOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-172
PROCEDURE TO CALIBRATION AFTER YOU ADJUST BODY POSITION SENSOR - - - - - - - - - - - - - - - 30-172
LOWER THE BODY MANUALLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-174
PROCEDURE TO LOWER THE BODY MANUALLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-174
LIFT THE BODY MANUALLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-175
PROCEDURE TO RAISE THE BODY MANUALLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-175
CAB AND ITS ATTACHMENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-176
30-4 HD465-8, HD605-8

30 TEST AND ADJUST CONTENTS
ADJUST STEERING WHEEL TILT LOCK LEVER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-176

PROCEDURE TO ADJUST STEERING WHEEL TILT LOCK LEVER - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-176
ADJUST RATTLING OPERATOR'S SEAT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-178
METHOD FOR ADJUSTING RATTLING OPERATOR'S SEAT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-178
SET AND ADJUST EACH EQUIPMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-179
SET AND OPERATE OF MACHINE MONITOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-182
OPERATOR MODE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-186
SERVICE MODE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-199
ABNORMALITY RECORD MENU - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-226
DEFAULT MENU - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-241
DIAGNOSTIC TESTS- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-257
ADJUSTMENT MENU - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-268
PROCEDURE TO CRANK WITH NO-INJECTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-295
PAYLOAD METER SETTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-297
PROCEDURE FOR MANUAL SNAP SHOT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-316
KOMTRAX SETTINGS MENU - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-319
PROCEDURE TO DISPLAY SERVICE MESSAGE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-321
PROCEDURE FOR STARTING UP KOMTRAX TERMINAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-323
DEFAULT SETTING OF KOMTRAX Plus CONTROLLER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-328
PROCEDURE FOR SETTING WITH DEFAULT SETTING OF KOMTRAX Plus CONTROLLER - - - - - - - - 30-328
SETTING DEFAULT OF WIRELESS LAN MODEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-330
PROCEDURE FOR SETTING DEFAULT OF WIRELESS LAN MODEM- - - - - - - - - - - - - - - - - - - - - - - - - 30-330
PROCEDURE TO CHECK WIRELESS LAN MODEM COMMUNICATION - - - - - - - - - - - - - - - - - - - - - - - 30-331
DOWNLOAD KOMTRAX Plus CONTROLLER DATA - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-332
PROCEDURE FOR DOWNLOAD OF KOMTRAX Plus CONTROLLER DATA- - - - - - - - - - - - - - - - - - - - - 30-332
ADJUST WHEN KOMTRAX Plus CONTROLLER IS REPLACED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-336
PROCEDURE TO ADJUST KOMTRAX Plus CONTROLLER WHEN REPLACED - - - - - - - - - - - - - - - - - - 30-336
ADJUST WHEN WIRELESS LAN MODEM IS REPLACED- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-339
PROCEDURE FOR ADJUSTMENT WHEN WIRELESS LAN MODEM IS REPLACED- - - - - - - - - - - - - - - 30-339
ADJUST REARVIEW CAMERA ANGLE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-341
PROCEDURE TO ADJUST REARVIEW CAMERA ANGLE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-341
ADJUST OPTICAL AXIS OF HEAD LAMP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-342
PROCEDURE TO ADJUST OPTICAL AXIS OF HEAD LAMP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-342
ENGINE CONTROLLER VOLTAGE CIRCUIT WORK - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-345
BATTERY DISCONNECT SWITCH WORK - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-346
TEST DIODES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-347
PROCEDURE TO TEST DIODE USING DIGITAL TESTER- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-347
PROCEDURE TO TEST DIODE USING ANALOG TESTER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-347
Pm CLINIC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-348
Pm CLINIC SERVICE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-348
Pm CLINIC CHECK SHEET: HD465-8- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-351
Pm CLINIC CHECK SHEET: HD605-8- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-357
PERFORMING QUICK Pm - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-363
PROCEDURE TO PERFORM QUICK Pm - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-363
HD465-8, HD605-8 30-5

ABBREVIATIONS 30 TEST AND ADJUST
ABBREVIATIONS

and system)

System

Advanced Joystick
Automatic Retarder
Automatic Retarder
the operator.




CDR Engine

Closed-center Load
Sensing System


30-6 HD465-8, HD605-8

30 TEST AND ADJUST ABBREVIATIONS

and system)

Electronic Control



Exhaust Gas
Recirculation



FOPS Cab and canopy
Structure

Global Positioning
System
Plus) location.

Global Navigation
Satellite System
Plus) location.

HSS

Hydro Static

Communication and
electronic control



HD465-8, HD605-8 30-7


and system)

KCCV Engine
filters.

KCSF Engine

KOMATSU Diesel
Oxidation Catalyst
muffler.

KDPF Engine
Particulate Filter
muffler.
KOMATSU Traction

such as a monitor.

LIN

load.
LVDS


Service
cell phones.

system
activated.

system
activated.
30-8 HD465-8, HD605-8

30 TEST AND ADJUST ABBREVIATIONS

and system)

PCCS
transmission.

supply pump.

Hydraulic system
(D, PC, etc)
PTP

ROPS Cab and canopy
Structure
ISO 12117-2.

SCR Urea SCR system
of related devices.



Tip-Over Protective
Structure
overturning)

VGT Engine

Variable HorsePower
Control
of the machine.

D: Bulldozer
HD: Dump truck
WA: Wheel loader
HD465-8, HD605-8 30-9

A/C Air Conditioner
A/M Air Mix damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
ENG Engine
F.G. Frame Ground
GND Ground
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/M Transmission
30-10 HD465-8, HD605-8

30 TEST AND ADJUST TOOLS TO TEST AND ADJUST
RELATED INFORMATION TO TEST AND ADJUST

TOOLS TO TEST AND ADJUST
Tools to test boost pressure
Symbol Part No. Part name Q'ty Remarks

- 799-201-2202 Boost gauge kit 1
A 1 799-401-2311 Gauge 1 Pressure range: -101 to 199.5 kPa
2 799-101-5160 Fitting 1 Size: R1/8
- 790-401-2301 Pm kit 1
B
1 790-261-1130 Coupling 1
Tools to test exhaust gas temperature

- 799-101-1502 Digital thermometer 1
A 1 79A-262-1910 Meter 1 Temperature range: -99.9 to 1299 ˚C
2 6215-11-8180 Sensor 1
Tools to test exhaust gas color

A 799-201-9002 Handy smoke checker 1
Commercially
- Smoke meter 1
available
Commercially
B 1 Probe 1
available
Commercially
2 Accelerator switch 1
available
Tools to test and adjust valve clearance

Commercially
A Feeler gauge 1
available
Tools to test compression pressure

A 795-502-1590 Compression gauge 1 Pressure range: 0 to 7 MPa
B 795-502-1810 Adapter 1
C 6219-71-1150 O-ring 2
D 6261-71-6150 Gasket 1
1 795-799-5410 Adapter 1
E
2 795-799-5420 Remover 1
HD465-8, HD605-8 30-11

TOOLS TO TEST AND ADJUST 30 TEST AND ADJUST
Tools to test blowby pressure

- 799-201-1506 Blowby checker 1
1 799-201-1591 Gauge 1 Pressure range: 0 to 10 kPa
A 2 799-201-1511 Tool 1
3 799-201-1450 Adapter 1
4 07281-00289 Clamp 2
Commercially
B Plug 2 Hose inside diameter: 23 mm
available
Commercially
C Cap 1 Tube outside diameter: 28.1 mm
available
Tools to test engine oil pressure

- 799-101-5002 Hydraulic tester 1
A
1 799-101-5160 Fitting 1 Size: R1/8
B 799-401-2320 Gauge 1 Pressure range: 1 MPa
Tools to test EGR valve and VGT oil pressure

A
1 799-101-5140 Gauge 1 Pressure range: 2.5 MPa
Tools to test fuel pressure

A
1 799-101-5160 Fitting 1 Size: R1/8
C 790-301-1210 Joint 1 Size: M14 x 1.5 - Rc1/8
D 07005-01412 Seal washer 1
E 790-301-1530 Elbow 1 Size: R1/8
30-12 HD465-8, HD605-8

Tools to test fuel return rate and leakage

A 6151-51-8490 Spacer 1
B 6206-71-1770 Joint 1
Commercially
C Hose 2 Inside diameter: About 19 mm
available
Commercially
D Stopwatch 1
available
Commercially
E Measuring cylinder 1
available
F 07005-01412 Seal washer 2
Commercially
G Oil container 1 Capacity: About 20 ℓ
available
H 07376-70422 Plug 1
Tools to test leakage in the fuel system

Commercially
A Developer for dye penetrant (color solution) 1
available
Tools to clean the fuel doser

Commercially
A Cloth 1
available
Commercially
B Diesel fuel - For cleaning
available
Commercially
C Nylon brush 1
available
Tools to program Trim code values of the injector and controller

Commercially
A
available
Laptop computer 1 Windows® 8 (32-bit)
B Cu3886388 INSITE 1
C 795-799-5732 INLINE 5 Kit 1
Commercially
D available or Cable (USB) 1
795-799-5742
E 795-799-5721 Cable 1
F 799-601-4510 Cable (12P) 1
HD465-8, HD605-8 30-13

Tools to test power train oil pressure

A 1 799-101-5130 Gauge 1 Pressure range: 6 MPa
B 790-261-1205 Digital hydraulic tester 1 Pressure range: 70 MPa
C 799-101-5220 Fitting 1 Size: M10 x 1.25 mm
D 07002-11023 O-ring 1
Tools to test and adjust steering oil pressure

A
1 799-101-5120 Gauge 1 Pressure range: 40 MPa
D 07002-11023 O-ring 1
Tools to test orbitrol valve pressure

A
D 07002-11023 O-ring 1
Tools to test steering cylinder pressure

2 799-101-5160 Fitting 1 Size: R1/8
C 799-401-3200 Adapter 2 Size: 03
Tools to test wheel brake oil pressure

A
2 799-101-5160 Fitting 1
3 790-301-1530 Elbow 1
C 793-520-1805 Brake test kit 1
30-14 HD465-8, HD605-8

Tools to test and adjust brake accumulator charge pressure

2 799-101-5160 Fitting 2 Size: R1/8
C 799-401-3200 Adapter 2 Size: 03
Tools to test nitrogen gas pressure in brake accumulator and charge nitrogen gas
Symbol Part No. Part name Q'ty Applicable standard

- 792-610-1703 Gas charging tool 1
A 1 792-610-2310 Extension 1
2 792-610-1260 Nipple (for Japan) 1 Size: W22-14 x W23-14
B 792-610-1270 Hose 1
C 792-610-2410 Bushing 1
D 792-610-1400 Regulator 1
792-610-1310 Nipple (for Russia) 1 GOST
792-610-1320 Nipple (for USA) 1 CGA No. 351
792-610-1330 Nipple (for USA) 1 ASA B-571-1965
E
DIN 477-1963
792-610-1350 Nipple (for Germany) 1 NEN 3268-1966
SIS-SMS2235/2238
792-610-1360 Nipple (for UK) 1 BS 341Part1-1962
Commercially
F Nitrogen gas cylinder 1
available
Tools to bleed air from the brake circuit

Commercially
A Hose 1 Inside diameter: About 8 mm
available
Commercially
B Oil container 1
available
Tools to test parking brake oil pressure

A
2 799-101-5160 Fitting 1
3 790-301-1530 Elbow 1
HD465-8, HD605-8 30-15

Tools to release parking brake manually

Commercially
A Oil container 1
available
q Size: M12 × 1.75
B 01017-51245 Bolt 20
q Length under neck: 65 to 80 mm
C 01580-1210 Washer 20 Size: M12
D 01643-1232 Nut 20 Size: M12
Tools to test front brake pad wear

A 566-98-41410 Gauge 1 Vehicle-mounted tool
Tools to test hoist circuit oil pressure

A
D 07002-11023 O-ring 1
Tools to test hoist cylinder pressure

A
D 07002-11023 O-ring 1
Tools to test hoist EPC valve circuit oil pressure

A
C 790-301-1210 Joint 1 Size: M14 x 1.5 - Rc1/8
D 799-101-5220 Fitting 2 Size: M10 x 1.25 mm
E 07002-11023 O-ring 2
F 799-401-3100 Adapter 1 Size: 02
30-16 HD465-8, HD605-8

Tools to test radiator fan circuit oil pressure

A
C 799-401-3500 Adapter 1 Size: 06
Tools to test and adjust front suspension cylinder

A 792-610-1001 Suspension tool 1
- 792-610-1101 Pump assembly 1
1 792-610-1130 Pump 1
B
2 792-610-1110 Hose 1
3 792-610-2200 Joint 1
- 792-610-1200 Charging tool assembly 1
1 07020-21732 Fitting 1
2 792-610-1140 Joint 1
3 792-610-1250 Valve assembly 1
C
4 792-610-1260 Fitting 1
5 792-610-1270 Hose 1
6 792-610-1280 Valve 1
7 792-610-1400 Regulator 1
D 792-610-1430 Gauge 1 Pressure range: 250 kg/cm2
E 792-610-1440 Gauge 1 Pressure range: 100 kg/cm2

Commercially
available
Commercially
G Oil pressure jack 1 Lift: Min. 50 t
available
HD465-8, HD605-8 30-17

Tools to test and adjust rear suspension cylinder

1 792-610-1130 Pump 1
B
2 792-610-1110 Hose 1
3 792-610-2200 Joint 1
1 07020-21732 Fitting 1
2 792-610-1140 Joint 1
C
4 792-610-1260 Fitting 1
5 792-610-1270 Hose 1
6 792-610-1280 Valve 1
7 792-610-1400 Regulator 1

Commercially
available
Commercially
G Block 1 Thickness: 19 mm
available
Tools to test KTCS circuit oil pressure

A
2 799-101-5160 Fitting 1
3 790-301-1530 Elbow 1
Tool to manually lift the body

A 792T-491-1110 Plug 1
Payload meter compensator

Commercially Total mass of maximum loading can be
A Load scale 1
available measured
30-18 HD465-8, HD605-8

Tools to set the default of KOMTRAX Plus controller
q Notebook type
Commercially
A
available
Personal computer 1 q Windows®7/8/8.1 based
q Equipped with LAN port
Commercially q Category: 5e
B LAN cable 1
available q Shape of connector: RJ45
Software for setting KOMTRAX Plus
C - Initial Configuration Tool 1
controller
Software for downloading the data from
D - Data Collection Tool 1
KOMTRAX Plus controller
Software for converting the downloaded
E - Data Conversion Tool 1
data
Tools to set the default of wireless LAN modem
q Notebook type
q Windows®7/8/8.1 based
Commercially q Equipped with LAN port
A Personal computer 1 q Equipped with wireless LAN port hav-
available
ing access point function
q Recommended product: "Panasonic
Let's note" AX/SX/MX Series
B LAN cable 1
Software for setting up a wireless LAN
C - Network Configuration Tool 1
modem
Tools to download the KOMTRAX Plus controller data
q Notebook type
available
B LAN cable 1
modem
data
HD465-8, HD605-8 30-19

Devises to adjust the KOMTRAX Plus controller when it is replaced
q Notebook type
Commercially
A
available
Personal computer 1 q Windows®7/8/8.1 based
B LAN cable 1
Software for setting KOMTRAX Plus
C - Initial Configuration Tool 1
controller
data
Devises to adjust the wireless LAN modem when it is replaced
q Notebook type
available
B LAN cable 1
modem
q Output: 24 V (1 A)
Commercially PoE power feeding adapter, or PoE power q Recommended product: "Ubiquiti
D 1
available feeding injector Networks, Inc." POE-24-2W,
POE-24-2W-G
30-20 HD465-8, HD605-8

30 TEST AND ADJUST DIAGRAM FOR TEST AND ADJUST TOOLS
DIAGRAM FOR TEST AND ADJUST TOOLS

Note: Komatsu does not take responsibility for special tools made by these illustrations.
Plug
Socket
HD465-8, HD605-8 30-21

TEST ENGINE SPEED 30 TEST AND ADJUST
ENGINE AND COOLING SYSTEM

TEST ENGINE SPEED
k Put the machine on a level ground, set the parking brake switch to (P), and stop the engine.
k Block the tires to prevent machine movement.
Do this check in these conditions.
q Engine coolant temperature: 60 to 100 ˚C (Engine speed at low idle: 65 to 100 ˚C)
q Transmission oil temperature: 70 to 90 ˚C
q Steering oil temperature: 45 to 55 ˚C
q Torque converter oil temperature: 60 to 80 ˚C
To perform the test to troubleshoot engine speed, refer to this section.
PROCEDURE TO TEST ENGINE SPEED
Procedure to test engine high idle speed
1. Start the engine.
2. Select and display "Pre-defined Monitoring" (01/28) or following monitoring items. For details, see "SET AND OPERATE
OF MACHINE MONITOR".
Monitoring code: 01002 "Engine Speed"
Monitoring code: 04107 "Coolant Temperature"
Monitoring code: 32701 "S/T Oil Temperature"
Monitoring code: 30100 "T/C Oil Temperature"
3. Make sure the coolant temperature and each oil temperatures are in the specified range.
4. Make sure that the body is seated correctly.
5. Set each control lever in NEUTRAL.
6. Measure the engine speed when the accelerator pedal is fully depressed (high idle).
For standard values, see STANDARD VALUE TABLE, "STANDARD VALUE TABLE FOR ENGINE".
Procedure to test engine low idle speed
The engine low idle speed is high and cannot be measured correctly if the aftertreatment devices regeneration is performed.
If the aftertreatment devices regeneration is shown, perform the measurement after aftertreatment devices regeneration is fin-
ished.
REMARK
When aftertreatment devices regeneration is completed, the after-
treatment pilot lamp goes off.

4. Make sure that the body is seated correctly.
5. Set each control lever in NEUTRAL.
30-22 HD465-8, HD605-8

30 TEST AND ADJUST TEST ENGINE SPEED
6. Measure the engine speed when the accelerator pedal is not depressed (low idle).
REMARK
Measure the engine speed at low idle when the AISS LOW switch is turned to ON or OFF.
Procedure to test engine speed at torque converter stall
For details to test the engine speed during torque converter stall, see "TEST TORQUE CONVERTER STALL SPEED".
HD465-8, HD605-8 30-23

TEST BOOST PRESSURE 30 TEST AND ADJUST
TEST BOOST PRESSURE

Tools to test boost pressure

- 799-201-2202 Boost gauge kit 1
A 1 799-401-2311 Gauge 1 Pressure range: -101 to 199.5 kPa
2 799-101-5160 Fitting 1 Size: R1/8
- 790-401-2301 Pm kit 1
B
1 790-261-1130 Coupling 1
k Be careful not to touch any hot part when you install or remove test tools.
q Engine coolant temperature: 60 to 100 ˚C
To perform the test to troubleshoot boost pressure, refer to this section.
BOOST PRESSURE TEST BY MACHINE MONITOR
2. Select and display "Pre-defined Monitoring" (01/28). For details, see "SET AND OPERATE OF MACHINE MONITOR".
4. Make sure the start-off gear speed is set to "F2" at "F1 Start at D
Position Setting" in the user menu.
NOTICE
If the start-off gear speed is selected other than "F2", the
machine may move while depressing the brake. Make sure
that "F2" (start-off gear speed) is selected in "F1 Start at D
5. Push the RETURN switch (12) to go back to "Service Menu"

screen. Select and display "Pre-defined Monitoring" (06/28) or
following monitoring items. For details, see "SET AND
OPERATE OF MACHINE MONITOR".
Monitoring code: 36500 "Charge Pressure"
Monitoring code: 37400 "Ambient Pressure"
30-24 HD465-8, HD605-8

30 TEST AND ADJUST TEST BOOST PRESSURE
6. Make sure the parking brake switch is in (P) position.
REMARK
The indicator lamp illuminates when the parking brake switch is
in operation.
7. Depress the brake pedal with the left foot to its travel end.
8. Shift the gear shift lever to D position to make sure that "F2" is
shown on the shift indicator.
9. Gradually depress the accelerator pedal, and measure the boost
pressure when the accelerator pedal is fully depressed.
k Hold the R.H. brake pedal fully depressed.
NOTICE
Do not stall the torque converter for more than 20 seconds.
Make sure the oil temperature of the torque converter does
not exceed 120 ˚C.
For standard values, see the absolute pressure in STAN-
DARD VALUE TABLE, "STANDARD VALUE TABLE FOR ENGINE".
REMARK
q Absolute pressure contains ambient pressure. Make sure the ambient pressure as it changes corresponding to the al-
titude.
Monitoring code: 37400 "Ambient Pressure"
q The relation between the absolute pressure and gauge pressure is as follows.
Absolute pressure = gauge pressure + ambient pressure
HD465-8, HD605-8 30-25

TEST BOOST PRESSURE 30 TEST AND ADJUST
PROCEDURE TO TEST BOOST PRESSURE WITH TEST TOOLS

1. Open the engine cover.
2. Remove boost pressure plug (1).
3. Install the fitting A2 of boost gauge kit A, and connect gauge A1.
3 Fitting A2:
2.0 to 3.9 Nm {0.2 to 0.4 kgm}
7. Set the connection part of gauge A1 and hose halfway, and drain the oil.
REMARK
q If Pm kit B is available, you can use air bleeding coupling B1 in the kit.
q Be sure to drain the oil. Otherwise, the gauge will not operate correctly.
NOTICE
30-26 HD465-8, HD605-8

30 TEST AND ADJUST TEST BOOST PRESSURE
REMARK
in operation.
10. Depress the brake pedal with the left foot to its travel end.
12. Gradually depress the accelerator pedal, and measure the boost
NOTICE
not exceed 120 ˚C.
For standard values, see the gauge pressure in "STANDARD
VALUE TABLE, STANDARD VALUE TABLE FOR ENGINE".
REMARK
q The gauge does not include ambient pressure.
q The relation between the gauge pressure and absolute pressure is as follows.
Gauge pressure = absolute pressure - ambient pressure
After you finish the test, remove the test tools and assemble the machine.
3 Pickup plug (1):
2.0 to 3.9 Nm {0.2 to 0.4 kgm}
HD465-8, HD605-8 30-27

TESTING EXHAUST GAS TEMPERATURE 30 TEST AND ADJUST
TESTING EXHAUST GAS TEMPERATURE

Tools to test exhaust gas temperature

- 799-101-1502 Digital thermometer 1
Temperature range: -99.9 to 1299
A 1 79A-262-1910 Meter 1
˚C
2 6215-11-8180 Sensor 1
k Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury. Wait until all
parts cool down before you start the work.
q Hydraulic oil temperature: 45 to 55 ˚C
To perform the test to troubleshoot exhaust gas temperature, refer to this section.
EXHAUST GAS TEMPERATURE TEST BY THE MACHINE MONITOR
1. Select and show these monitor items. For details, see "SET AND OPERATE OF MACHINE MONITOR".
Monitoring code: 42602 "Exhaust Air Temperature"
3. Measure the exhaust gas temperature.
q Procedure to troubleshoot the maximum value of the exhaust temperature
REMARK
q Measure the maximum value of the exhaust temperature when the operation is performed.
q The exhaust temperature differs largely because of outer air temperature (engine intake air temperature). When
an unusual value is measured, correct the value with this formula.
Correction value [˚C] = measured value + 2 × (20 - ambient temperature)
q Procedure for regular inspections and PM Clinics tests
Measure the exhaust temperature while torque converter stall is performed.
NOTICE
When you stall the torque converter, the torque converter becomes too hot before the exhaust temperature
becomes stable. To avoid this situation, increase the exhaust gas temperature in full stall (torque converter
stall + oil pressure relief). Then stall the torque converter, and measure the exhaust temperature.
1) Start the engine and increase the engine water temperature in between 60 to 100 ˚C.
30-28 HD465-8, HD605-8

30 TEST AND ADJUST TESTING EXHAUST GAS TEMPERATURE
2) Make sure the start-off gear speed is set to "F2" at "F1

Start at D Position Setting" in the user menu.
NOTICE
If the start-off gear speed is selected other than "F2",
the machine may move while depressing the brake.
Make sure that "F2" (start-off gear speed) is selected
in "F1 Start at D Position Setting" in the user menu.
3) Make sure the parking brake switch is in (P) position.

REMARK
The indicator lamp illuminates when the parking brake
switch is in operation.
4) Depress the brake pedal with the left foot to its travel end.
5) Shift the gear shift lever to D position to make sure that

"F2" is shown on the shift indicator.
6) Gradually depress the accelerator pedal fully (high idle).
Perform the torque converter stall and oil pressure relief
(full stall). Move the dump lever to the lower position at
the same time.
NOTICE
q Do not shift the gear shift lever to other than D po-
sition during the torque converter stall. Other-
wise the inner part of the transmission may burst.
q Do not stall the torque converter for more than 20 seconds. Make sure the oil temperature of the torque
converter does not exceed 120 ˚C.
REMARK
Hold the engine RPM until the exhaust temperature becomes stable.
7) When the exhaust temperature becomes stable, move the dump lever to the neutral position. Measure the exhaust
temperature with only the torque converter at stall.
REMARK
q As the exhaust temperature decreases from the full stall, measure the temperature in a stable condition.
q If the exhaust temperature does not decrease but increases, set the high temperature at the full stall.
8) Lift your right foot off the accelerator pedal, and return the gear shift lever to N position.
HD465-8, HD605-8 30-29

TESTING EXHAUST GAS TEMPERATURE 30 TEST AND ADJUST
PROCEDURE TO TEST EXHAUST GAS TEMPERATURE

1. Remove the exhaust gas temperature pickup plug (1).
REMARK
When the cover is attached, remove the cover and then remove
the exhaust gas temperature pickup plug (1).
2. Connect the sensor A2 in the digital thermometer A and connect

it to meter A1.
REMARK
Make sure the harness of the digital meter does not touch any hot
parts during the procedure.
3. Measure the exhaust gas temperature.
q Procedure to obtain the maximum value when you trouble-
shoot
REMARK
q Measure the maximum value of the exhaust temper-
ature when the operation is performed.
q The exhaust temperature differs largely because of
outer air temperature (engine intake air temperature).
When an unusual value is measured, correct the val-
ue with this formula.
Correction value [˚C] = measured value + 2 × (20 -
ambient temperature)
q Use the PEAK mode of digital thermometer.
q Procedure for regular inspections and PM Clinics tests
Measure the exhaust temperature while torque converter
stall is performed.
NOTICE
When you stall the torque converter, the torque converter becomes too hot before the exhaust temperature be-
comes stable. To avoid this situation, increase the exhaust gas temperature in full stall (torque converter stall +
oil pressure relief). Then stall the torque converter, and measure the exhaust temperature.
1) Start the engine and increase the engine water temperature in between 60 to 100 ˚C.
2) Make sure the start-off gear speed is set to "F2" at "F1
Start at D Position Setting" in the user menu.
NOTICE
If the start-off gear speed is selected other than "F2",
the machine may move while depressing the brake.
Make sure that "F2" (start-off gear speed) is selected
in "F1 Start at D Position Setting" in the user menu.
30-30 HD465-8, HD605-8

30 TEST AND ADJUST TESTING EXHAUST GAS TEMPERATURE
3) Make sure the parking brake switch is in (P) position.

REMARK
The indicator lamp illuminates when the parking brake switch
is in operation.
4) Depress the brake pedal with the left foot to its travel end.
5) Shift the gear shift lever to D position to make sure that

"F2" is shown on the shift indicator.
6) Gradually depress the accelerator pedal fully (high idle).
Perform the torque converter stall and oil pressure relief
(full stall). Move the dump lever to the lower position at
the same time.
NOTICE
q Do not shift the gear shift lever to other than D po-
sition during the torque converter stall. Other-
wise the inner part of the transmission may burst.
q Do not stall the torque converter for more than 20 seconds. Make sure the oil temperature of the torque
converter does not exceed 120 ˚C.
REMARK
Hold the engine RPM until the exhaust temperature becomes stable.
7) When the exhaust temperature becomes stable, move the dump lever to the neutral position. Measure the exhaust
temperature with only the torque converter at stall.
REMARK
q As the exhaust temperature decreases from the full stall, measure the temperature in a stable condition.
q If the exhaust temperature does not decrease but increases, set the high temperature at the full stall.
3 Plug (1):
2.9 to 5.9 Nm {0.3 to 0.6 kgm}
2 Plug (1):
Seizure prevention compound (LC-G)
HD465-8, HD605-8 30-31

TEST EXHAUST GAS COLOR 30 TEST AND ADJUST
TEST EXHAUST GAS COLOR

Tools to test exhaust gas color

A 799-201-9002 Handy smoke checker 1
- Commercially available Smoke meter 1
B 1 Commercially available Probe 1
2 Commercially available Accelerator switch 1
k Be careful not to burn you with high exhaust temperatures which may leak from the inspection port when after-
treatment regeneration is performed. Be sure to disable it with "Regeneration Disable" on the machine monitor
before you test. (For details of "Regeneration Disable" operation, see Operation and Maintenance Manual.)
REMARK
q When the body heating is not performed, perform the procedures from step 4 and measure at the exhaust pipe outlet.
q When the body heating is performed, perform the procedures from step 1 and check at measuring port of KDPF inlet piping.
q After you have held normal condition for 5 seconds, collect the exhaust gas sample.
When in the field and an air source or electric power are not available, use the handy smoke checker A. When recording official
data, use smoke meter B.
To perform the test to troubleshoot exhaust gas color, refer to this section.
TEST EXHAUST GAS COLOR WITH THE HANDY SMOKE CHECKER
2. Remove the plug (1).
30-32 HD465-8, HD605-8

30 TEST AND ADJUST TEST EXHAUST GAS COLOR
3. Install a sheet of filter paper to handy smoke checker A.

4. Engage the exhaust gas intake pipe of handy smoke checker A
into removed plug (1) port or exhaust pipe outlet (b).
5. Run the engine at high idle, and stall the torque converter. For
details, see "TEST ENGINE SPEED".
6. Operate the handle of handy smoke checker A, and collect the
exhaust gas to the filter paper while the engine operates at high
idle and the torque converter stalled.
REMARK
Suction time: 1.4 ± 0.2 seconds
7. Remove the filter paper and compare it with the attached scale
for analysis.
For standard values, see STANDARD VALUE TABLE, "STAN-
DARD VALUE TABLE FOR ENGINE".
After you finish the test, remove the test tools and assemble the ma-
chine.
2 Plug (1):
3 Plug (1):
26.5 to 43.1 Nm {2.7 to 4.4 kgm}
TEST EXHAUST GAS COLOR WITH SMOKE METER

HD465-8, HD605-8 30-33

TEST EXHAUST GAS COLOR 30 TEST AND ADJUST
3. Engage the probe B1 of smoke meter B into removed plug (1)

port (a) or exhaust pipe outlet (b).
4. Turn on the smoke meter B.
REMARK
For the operation procedure, see Operation and Maintenance
Manual of smoke meter B.
6. Select and display "Pre-defined Monitoring" (01/28). For details,
see "SET AND OPERATE OF MACHINE MONITOR".
7. Make sure the coolant temperature and the torque converter oil
temperature are in the specified range.
8. Run the engine at high idle, and stall the torque converter. For
details, see "TEST ENGINE SPEED" and "TEST TORQUE CONVERTER STALL SPEED".
9. Depress accelerator switch B2 of smoke meter B, and collect the exhaust gas to the filter paper while the engine operates
at high idle and the torque converter stalled.
10. Place the contaminated filter paper on the clean filter paper (minimum 10 sheets) in the filter paper holder and read the
indicated value.
2 Plug (2):
3 Plug (2):
26.5 to 43.1 Nm {2.7 to 4.4 kgm}
30-34 HD465-8, HD605-8

30 TEST AND ADJUST TEST AND ADJUST VALVE CLEARANCE
TEST AND ADJUST VALVE CLEARANCE

Tools to test and adjust valve clearance

A Commercially available Feeler gauge 1
k Make sure that the system operation lamp is off, turn the battery disconnect switch to OFF position.
Do this check and adjustment in these conditions.
Engine coolant temperature: Normal temperature
To perform the test and adjustment to troubleshoot valve clearance, refer to this section.
TEST VALVE CLEARANCE
1. Remove the cylinder head cover of the cylinder to be checked. For details, see DISASSEMBLY AND ASSEMBLY,
"REMOVE AND INSTALL INJECTOR ASSEMBLY".
2. Remove the plug (1) or plug (1a) from the inspection hole at the
left side of engine.
3. Pull out the pin (3) of cranking device (2), and push the shaft (4).
4. Rotate the shaft (4) counter-clockwise, then turn the crankshaft

(4) clockwise and set notch (b) of the supply pump drive gear to
the middle of inspection hole (a).
REMARK
When notch (b) is set, No. 1 cylinder is at top dead center of com-
pression.
When notch (c) is set, No. 6 cylinder is at top dead center of com-
pression.
HD465-8, HD605-8 30-35

TEST AND ADJUST VALVE CLEARANCE 30 TEST AND ADJUST
5. While No. 1 cylinder is at top dead center of compression,

measure the valve clearance identified with ● in the figure.
REMARK
Insert the feeler gauge A into the clearance between rocker arm
(5) and crosshead (6) to measure the valve clearance.
6. Rotate the crankshaft clockwise by 1 turn and measure the valve
clearance of the remaining valves identified with ○.
REMARK
q You may measure the valve clearance of No. 1 cylinder while
No. 1 cylinder is at top dead center of compression. Then turn
the crankshaft in the normal direction 120 ° at a time and
measure the valve clearance of each cylinder in the firing se-
quence.
q Firing sequence: 1-5-3-6-2-4
After you finish the test, assemble the machine.
3 Plug (1):
58.8 to 78.4 Nm {6 .0 to 8.0 kgm}
3 Plug (1):
44.1 to 53.9 Nm {4.5 to 5.5 kgm}
ADJUST VALVE CLEARANCE

After you test, adjust the valve clearance according to the following procedure, if necessary.
Set the No. 1 cylinder at top dead center of compression, and adjust valve clearance on No. 1 cylinder.
1. While you hold the adjustment screw (7), loosen the locknut (8).
2. Engage the feeler gauge A into the clearance between rocker
arm (5) and crosshead (6), and adjust the valve clearance with
adjustment screw (7).
REMARK
q Turn the adjustment screw (7) with the feeler gauge A en-
gaged, and adjust the screw (7) until clearance is equal to the
feeler gauge A dimension.
q For standard values, see STANDARD VALUE TABLE,
"STANDARD VALUE TABLE FOR ENGINE".
3. While you hold the adjustment screw (7), tighten the locknut (8).
3 Locknut (8):
57.8 to 77.4 Nm {5.9 to 7.9 kgm}
After you tighten the locknut (8), measure the valve clearance again.
REMARK
q You may adjust the valve clearance of No. 1 cylinder while No. 1 cylinder is at top dead center of compression. Then
turn the crankshaft in the normal direction 120 ° at a time and adjust the valve clearance of each cylinder in the firing
sequence.
q Firing sequence: 1-5-3-6-2-4
After you finish the adjustment, remove the adjustment tools and assemble the machine.
30-36 HD465-8, HD605-8

30 TEST AND ADJUST TEST AND ADJUST VALVE CLEARANCE
NOTICE
The tighten value for No. 5 head cover is different.
3 Bolts of cylinder head cover (No. 1, No. 2, No. 3, No. 4, and No. 6 cylinders):
56 to 74 Nm {6.0 to 7.5 kgm}
3 Bolts of cylinder head cover (No. 5 cylinder):
9.8±1 Nm {1.0±0.1 kgm}
HD465-8, HD605-8 30-37

COMPRESSION TEST 30 TEST AND ADJUST
COMPRESSION TEST
Tools to test compression pressure

A 795-502-1590 Compression gauge 1 Pressure range: 0 to 7 MPa
B 795-502-1810 Adapter 1
C 6219-71-1150 O-ring 2
D 6261-71-6150 Gasket 1
1 795-799-5410 Adapter 1
E
2 795-799-5420 Remover 1
k Turn the battery disconnect switch to OFF position.
k When you test the compression pressure, be careful you do not become burned by exhaust manifold or KDPF, or
become caught in parts that rotate.
q Engine speed: 210 to 250 rpm (reference)
To perform the test to troubleshoot compression pressure, refer to this section.
COMPRESSION PRESSURE TEST
1. Remove the cylinder head cover of the cylinder to be checked. For details, see DISASSEMBLY AND ASSEMBLY,
"REMOVE AND INSTALL INJECTOR ASSEMBLY".
2. Set the cylinders to be checked to the compression top dead center. For details, see "TEST AND ADJUST VALVE CLEAR-
ANCE".
REMARK
Make sure that the intake rocker arm and exhaust rocker arm at top dead center of compression move by hand equal to
the valve clearance.
3. Remove the clamp (1) that holds the high-pressure pipe of the
cylinder to be checked. For details, see DISASSEMBLY AND
ASSEMBLY, "REMOVE AND INSTALL INJECTOR
ASSEMBLY".
REMARK
q Remove the clamp (1) for easy removal of the high-pressure
pipe engaged in the injector.
q It is not necessary to remove the clamp (2) on the common
rail side.
30-38 HD465-8, HD605-8

30 TEST AND ADJUST COMPRESSION TEST
4. Remove the bolts (3) and (4), and remove the injector harness
(5).
5. Loosen the sleeve nut, and disconnect the high-pressure pipe
from the injector (8).
6. Remove the holder (6).
7. Engage the end of adapter E1 into hole (a) of adapter (9), and
pull out injector (8) by movement of removal tool E2 up and
down.
REMARK
There is QR code label on the top of injector (8). Do not remove
or damage it.
8. Fit the O-ring C and gasket D to the end of adapter B.

9. Install the adapter (9), installed to injector (8), to adapter B.
HD465-8, HD605-8 30-39

COMPRESSION TEST 30 TEST AND ADJUST
10. Engage the adapter B together with adapter (9) into the injector
mount hole, and connect compression gauge A.
REMARK
Apply a small amount of engine oil to the connecting portion of
adapter B and compression gauge A to prevent air leakage.
11. Fix the adapter B with the injector holder.

3 Holder mount bolt:
58.9 to 73.5 Nm {6.0 to 7.5 kgm}
12. Turn the battery disconnect switch to ON position, then turn the start switch to ON position.
13. Set the machine monitor to "No-Injection Cranking". For details, see "SET AND OPERATE OF MACHINE MONITOR".
k It is dangerous if "No-Injection Cranking" mode is not selected because engine will start. Be sure to set the
engine in this mode.
30-40 HD465-8, HD605-8

30 TEST AND ADJUST COMPRESSION TEST
14. Measure the compression pressure when the engine is cranked by the starting motor.
NOTICE
Do not crank the engine for 20 seconds or longer to protect the starting motor.
REMARK
Read the compression pressure when the pointer of gauge is stabilized.
Procedure to install injector and high pressure fuel tube
NOTICE
q Before you install the injector (8), replace the gasket (10) and O-rings (11) and (12) with new ones.
q Never install O-ring (11) to groove (b).
1. Install the adapter (9) to injector (8).
2. Push in the injector (8) together with adapter (9) with the hand,
and lightly assemble the holder (13).
3. Apply engine oil to the spherical portion of washer (15).
4. Tighten bolt (14) and washer (15) lightly.
5. Lightly tighten the sleeve nut (16) of the fuel high-pressure pipe.
6. Tighten the bolt (14) to the specified value.
3 Bolt (14):
58.9 to 73.5 Nm {6.0 to 7.5 kgm}
7. Tighten the sleeve nut (16) to the specified value.
3 Sleeve nut (16):
39.2 to 44.1 Nm {4.0 to 4.5 kgm}
8. Install the injector harness (5).

9. Tighten the nut.
3 Nut (4):
2±0.2 Nm {0.2±0.02 kgm}
3 Bolt (3):
27 to 34 Nm {2.8 to 3.5 kgm}
NOTICE
The tighten value for No. 5 head cover is different.
3 Bolts of cylinder head cover (No. 1, No. 2, No. 3, No. 4, and
No. 6 cylinders):
56 to 74 Nm {6.0 to 7.5 kgm}
3 Bolts of cylinder head cover (No. 5 cylinder):
9.8±1 Nm {1.0±0.1 kgm}
HD465-8, HD605-8 30-41

BLOWBY PRESSURE TEST 30 TEST AND ADJUST
BLOWBY PRESSURE TEST

Tools to test blowby pressure

- 799-201-1506 Blowby checker 1
1 799-201-1591 Gauge 1 Pressure range: 0 to 10 kPa
A 2 799-201-1511 Tool 1
3 799-201-1450 Adapter 1
4 07281-00289 Clamp 2
B Commercially available Plug 2 Hose inside diameter: 23 mm
C Commercially available Cap 1 Tube outside diameter: 28.1 mm
To perform the test to troubleshoot blowby pressure, refer to this section.
BLOWBY PRESSURE TEST
2. Remove the clamps and disconnect the KCCV blowby gas inlet
side hoses (1) and outlet side hose (2).
30-42 HD465-8, HD605-8

30 TEST AND ADJUST BLOWBY PRESSURE TEST
3. Put the caps C to the blowby gas inlet side and outlet side of
KCCV.
4. Install the plug B to the outlet side hose.
5. Insert the tool A2 of blowby checker A into KCCV inlet hose (3),
and connect the gauge A1 to pipe A3.
8. Make sure the coolant temperature and the torque converter oil temperature are in the specified range.
NOTICE
11. Gradually depress the accelerator pedal, and test the blowby
NOTICE
not exceed 120 ˚C.
REMARK
q Usually, the blow-by pressure should be measured while the engine is operated at the rated output. In the field, how-
ever, an approximate value is obtained while you stall the torque converter.
q Blowby pressure varies with the condition of the engine. If the value by the test is considered unusual, perform inspec-
tion for phenomena such as excessive oil consumption, bad color of exhaust gas, early oil deterioration, early oil con-
tamination, which are related to blowby problems.
3 Clamp of hoses (1) and (2):
4.4±0.49 Nm {0.45±0.05 kgm}
HD465-8, HD605-8 30-43

TEST ENGINE OIL PRESSURE 30 TEST AND ADJUST
TEST ENGINE OIL PRESSURE

Tools to test engine oil pressure

A
1 799-101-5160 Fitting 1 Size: R1/8
q Engine coolant temperature: 60 °C and above (at high idle)
q Engine coolant temperature: 65 °C and above (at high idle)
To perform the test to troubleshoot engine oil pressure, refer to this section.
ENGINE OIL PRESSURE TEST BY MACHINE MONITOR
3. Make sure the coolant temperature is in the specified range.
REMARK
q When the engine coolant temperature is 65 ˚C or less, the en-
gine speed at low idle becomes higher because of the engine
automatic warm-up function. For precise measurement, raise
the engine coolant temperature to 65 °C and above when
checking at low idle.
q Measure with the AISS LOW switch to OFF position.
4. Measure the engine oil pressure when the accelerator pedal is fully depressed (high idle) and when the accelerator pedal
is not depressed (low idle).
TEST ENGINE OIL PRESSURE
1. Remove the oil pressure pickup plug (1).
REMARK
When the cover is attached on the machine, remove the cover
and then remove the oil pressure pickup plug (1).
30-44 HD465-8, HD605-8

30 TEST AND ADJUST TEST ENGINE OIL PRESSURE
2. Install the fitting A1 of hydraulic tester A, and connect the gauge

B.
3 Fitting A1:
6.9 to 14.7 Nm {0.7 to 1.5 kgm}
REMARK
6. Measure the engine oil pressure when the accelerator pedal is
fully depressed (high idle) and when the accelerator pedal is not
depressed (low idle).
3 Pickup plug (1):
6.9 to 14.7 Nm {0.7 to 1.5 kgm}
HD465-8, HD605-8 30-45

EGR VALVE AND VGT OIL PRESSURE TEST 30 TEST AND ADJUST
EGR VALVE AND VGT OIL PRESSURE TEST

Tools to test EGR valve and VGT oil pressure

A
Engine coolant temperature: 60 to 100 ˚C
To perform the test to troubleshoot EGR valve and VGT oil pressure, refer to this section.
EGR VALVE AND VGT OIL PRESSURE TEST
1. Connect the gauge A1 of hydraulic tester A to the fitting (1) at the
right side of engine.
REMARK
When the cover is attached on the machine, remove the cover
and then connect gauge A1 of hydraulic tester A.
REMARK
5. Measure the oil pressure when the accelerator pedal is fully
depressed (high idle) and when the accelerator pedal is not
depressed (low idle).
30-46 HD465-8, HD605-8

30 TEST AND ADJUST FUEL PRESSURE TEST
FUEL PRESSURE TEST

Tools to test fuel pressure

A
1 799-101-5160 Fitting 1 Size: R1/8
C 790-301-1210 Joint 1 Size: M14 x 1.5 - Rc1/8
D 07005-01412 Seal washer 1
E 790-301-1530 Elbow 1 Size: R1/8
k Since the pressure in the high-pressure circuit from the supply pump through the common rail to the injector is
very high and dangerous, do not measure it.
k Wait for the remaining pressure in the fuel circuit to be released at least 30 seconds after stopping the engine.
Then, perform removing or installing the test tools. (Do not start the work immediately after the engine is stopped
since remaining pressure is still in the circuit.)
NOTICE
Measure the fuel pressure in the low-pressure circuit from the feed pump through the fuel main filter to the supply
pump.
To perform the test to troubleshoot fuel pressure, refer to this section.
FUEL PRESSURE TEST
1. Remove the plug (1) on the fuel filter inlet side.
2. After installing the joint C and the elbow E, install the fittings A1
of hydraulic tester A, and connect gauge B.
REMARK
When you install the joint C, install the seal washer D.
3 Joint C:
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
HD465-8, HD605-8 30-47

FUEL PRESSURE TEST 30 TEST AND ADJUST

6. Measure the fuel pressure when the accelerator pedal is fully
depressed (high idle).
chine.
3 Plug (1):
19.6 to 24.5 Nm {2.0 to 2.5 kgm}
30-48 HD465-8, HD605-8

30 TEST AND ADJUST FUEL RETURN RATE AND LEAKAGE TEST
FUEL RETURN RATE AND LEAKAGE TEST

Tools to test fuel return rate and leakage

A 6151-51-8490 Spacer 1
B 6206-71-1770 Joint 1
C Commercially available Hose 2 Inside diameter: About 19 mm
D Commercially available Stopwatch 1
E Commercially available Measuring cylinder 1
F 07005-01412 Seal washer 2
G Commercially available Oil container 1 Capacity: About 20 ℓ
H 07376-70422 Plug 1
k Wait for the remaining pressure in the fuel circuit to be released at least 30 seconds after stopping the engine.
Then, perform removing or installing the test tools. (Do not start the work immediately after the engine is stopped
since remaining pressure is still in the circuit.)
To perform the test to troubleshoot fuel return rate and leakage, refer to this section.
HD465-8, HD605-8 30-49

FUEL RETURN RATE AND LEAKAGE TEST 30 TEST AND ADJUST
FUEL RETURN RATE AND LEAKAGE TEST

The figure shows the flow of fuel and measuring positions.
A: Test position for leakage of pressure limiter valve 7: Main filter

B: Test position for fuel return rate from injector 8: Fuel feed pump-B
1: Fuel tank 9: Fuel feed pump-A
2: Prefilter 10: Fuel doser solenoid valve assembly-B
3: Supply pump-B 11: Fuel doser solenoid valve assembly-A
4: Supply pump-A 12: Fuel doser-B
5: Common rail 13: Fuel doser-A
6: Injector
30-50 HD465-8, HD605-8

30 TEST AND ADJUST FUEL RETURN RATE AND LEAKAGE TEST
Pressure limiter valve leak test

1. Remove the clamp (3) from the fuel pipe (5) on the left side of
engine.
REMARK
q When the cover is attached on the machine, remove the cov-
er and then remove the clamp.
q The fuel pipe (5) is installed between the pressure limiter (2)
and the return circuit relay block (2a).
2. Loosen the joint (4) and move the pipe (5) toward you.
3. Engage the spacer A alternative to the pipe (5), and tighten the
joint bolt (4).
3 Joint bolt (4):
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
REMARK
When you install spacer A, install the seal washers F to two ends
of spacer A.
4. Connect the test hose C to the end of pipe (5).
REMARK
q Bind the connection part of test hose C with a wire to secure
the connection.
q Adjust the routing of test hose C to hold tension and engage
its end to measuring cylinder E.
6. Stall the torque converter. For details, see "TEST TORQUE
CONVERTER STALL SPEED".
7. After the engine speed is stable, measure the quantity that leaks
from the pressure limiter for 1 minute with measuring cylinder E.
REMARK
To correctly judge, use the leakage quantity obtained from the
test of 20 seconds and multiply by 3.
8. Stop the engine.
chine.
3 Joint bolt (4):
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
HD465-8, HD605-8 30-51

FUEL RETURN RATE AND LEAKAGE TEST 30 TEST AND ADJUST
Test fuel return rate from injector

1. Disconnect the fuel return hose (6) of the return block.
REMARK
Plug the fuel hose side with plug H.
2. Connect the test hose C.
REMARK
q Bind the connection part of test hose C with a wire to secure
the connection.
q Adjust the routing of test hose C to hold tension and engage
its end to measuring cylinder E.
4. Stall the torque converter. For details, see "TEST ENGINE
SPEED".
5. After the engine speed is stable, measure the return rate for 1
minute with measuring cylinder E.
REMARK
q To correctly judge, use the leakage quantity obtained from
the test of 20 seconds and multiply by 3.
q When failure code [CA559] or [CB559] for "Common Rail
Pressure Low Error 1" and [CA2249] or [CB2249] for "Com-
mon Rail Pressure Low Error 2" are shown, the engine speed
may not increase. In this case, also record the engine speed
during the test.
6. Stop the engine.
30-52 HD465-8, HD605-8

30 TEST AND ADJUST BLEEDING AIR FROM FUEL SYSTEM
BLEEDING AIR FROM FUEL SYSTEM

k While the fuel feed pump is in operation, pressure is applied to the fuel circuit. Do not loosen the air bleeding plug
at this time, since the fuel may spurt out.
To perform the air bleed from fuel system to troubleshoot, refer to this section.
BLEED AIR FROM FUEL SYSTEM
In these cases, bleed air corresponding to this procedure.
q When the fuel filters are replaced
q When the machine run out of fuel
q When you start the engine for the initial time after you replace fuel piping or supply pump
1. Turn the start switch to ON position, and make sure the fuel level
caution lamp is not illuminated in red.
REMARK
If the fuel level caution lamp is illuminated in red, the fuel level is
low. In this case, add fuel.
2. Turn the start switch to OFF position.

3. Set the fuel feed pump switch (1) to ON position.
REMARK
q The timer is assembled in the fuel feed pump, and after the
switch is turned on, the fuel feed pump automatically repeats
the same operation 10 times.
q The fuel feed pump stops while the lamp flashes, but this is
normal, not an error.
q If the switch is turned to OFF position while the lamp flashes,
the lamp goes out and the fuel feed pump stops.
4. After the specified time (approximately 6 minutes 30 seconds),
the lamp (2) goes out and the fuel feed pump stops automatically.
When the fuel filter alone is replaced, the air bleed procedure is
completed.
5. When fuel in the fuel circuit is lost in the cases as fuel has run out
or the fuel piping or supply pump is replaced, set the switch (1)
to ON position again immediately after the fuel feed pump stops
automatically.
6. When the lamp (2) goes out, air bleed procedure is completed.
HD465-8, HD605-8 30-53

BLEEDING AIR FROM FUEL SYSTEM 30 TEST AND ADJUST
7. Start the engine by cranking it with the starting motor.

k Make sure no one is around the engine before you start
the engine.
NOTICE
To protect the starting motor, do not crank the engine for
longer than 20 seconds.
REMARK
q The air in the high-pressure circuit is bled automatically by
cranking the engine.
q After the engine starts, run it at low idle for approximately 5
minutes to bleed all air from the fuel circuit.
30-54 HD465-8, HD605-8

30 TEST AND ADJUST FUEL CIRCUIT LEAK TEST
FUEL CIRCUIT LEAK TEST

Tools to test leakage in the fuel system

Developer for dye penetrant (color
A Commercially available 1
solution)
k Fuel leakage may result in a dangerous fire because of high pressure generated in the high-pressure circuit of the
fuel system during engine operation. When you examine the fuel circuit or remove a component, make sure that
no fuel leaks by complete of these procedures.
Clean the engine and parts around it, and degrease them in advance to easily examine for leaks.
To perform the test to troubleshoot fuel system for leakage, refer to this section.
FUEL CIRCUIT LEAK TEST
Procedure to test fuel circuit for leakage when engine stops
2. The engine stops when the accelerator pedal is not depressed (low idle) and the engine automatic warm-up function is
canceled automatically, and the engine seed becomes stable.
REMARK
For details of the condition for cancellation of the engine automatic warm-up function, see STRUCTURE AND FUNCTION,
"ENGINE AUTOMATIC WARM-UP FUNCTION".
3. Spray color solution A to the connection part of the supply pump, common rail, injector, and high pressure pipes.
4. Examine for fuel leaks of the fuel piping and devices.
q Examine for fuel leaks of high pressure circuit focusing around the part where color solution A is sprayed.
q If there is a fuel leak, repair the leak and perform the inspection from step 1.
Procedure to test fuel circuit for leakage with engine speed at low idle
REMARK
REMARK
Do not depress the accelerator pedal.
5. Stop the engine and examine for fuel leaks of the fuel piping and devices.
Procedure to test fuel circuit for leakage with engine speed at high idle
REMARK
HD465-8, HD605-8 30-55

FUEL CIRCUIT LEAK TEST 30 TEST AND ADJUST
4. Start the engine and depress the accelerator pedal to travel end. (high idle)
Procedure to test fuel circuit for leakage with torque converter stalled
REMARK
5. Apply the load on the engine. For details, see "TEST TORQUE CONVERTER STALL SPEED".
30-56 HD465-8, HD605-8

30 TEST AND ADJUST SUPPLY PUMP TEST
SUPPLY PUMP TEST

Refer to this section, if the supply pump is defective and no other problems are found after you perform TROUBLESHOOTING,
"TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)" or or "TROUBLESHOOTING OF ENGINE (S MODE)".
The test identifies the defective pump (supply pump-A or supply pump-B).
SUPPLY PUMP TEST
2. Select and show these monitor items. For details, see "SET AND
Monitoring code: 17201 "PCV Close Timing (TDC Standard)"
Monitoring code: 31706 "Final Throttle Position"
Monitoring code: 42700 "Engine Oil Temperature"
Monitoring code: 18600 "Inject Fueling Command"
4. Depress the accelerator pedal to travel end (high idle) and make
sure the value of "PCV Close Timing (TDC Standard)" and "Engine Speed" when the values of "Final Throttle Position" is
100 %.
REMARK
Record the test results to compare with other results corresponding to the procedures that follow.
6. Make sure that the system operation lamp is not illuminated.
7. Disconnect the PCV connectors of supply pump one at a time in
the same sequence as this table. Each time the connector is
disconnected, perform steps 1 through 6.
REMARK
Failure codes are shown during the test because the engine is
running without PCV connectors connected.
HD465-8, HD605-8 30-57

SUPPLY PUMP TEST 30 TEST AND ADJUST
Procedure Supply pump PCV connector Reported error

1 P1_PCV1 [CA272]
Supply pump-A (1)
2 P1_PCV2 [CA274]
3 P2_PCV1 [CB272]
Supply pump-B (2)
4 P2_PCV2 [CB274]
8. Compare the value of "PCV Close Timing (TDC Standard)" measured in step 4 and the value of "PCV Close Timing (TDC
Standard)" measured in step 7 to identify a defective supply pump.
NOTICE
When 10 rpm or more is the difference in the maximum and minimum "Engine Speed" compared to "PCV Close
Timing (TDC Standard)", the engine operating conditions changed. The value of "PCV Close Timing (TDC Stan-
dard)" effect the operation conditions of engine. When the difference of "Engine Speed" is 10 rpm or more, con-
nect the disconnected PCV connector again and repeat the testing procedure from step 1.
REMARK
Measure "PCV Close Timing (TDC Standard)" value before and after you connect connectors. If the measured value differs
by 2 CA or more, supply pumps performs correctly. If the measured value does not differ by 2 CA or more, the supply pump
of disconnected PCV connector is defective.
q Supply pump-A (1) might be defective when:
There is not a larger difference than 2 CA between standard value and the value when the connector (P1_PCV1) is dis-
connected. The supply pump-A (1) may be defective.
PCV Close Timing

Removed connectors Difference value (CA) Result
Supply pump (TDC Standard)(CA)
- 54.5 (standard value) - -
P1_PCV1 53.5 1.0
Supply pump-A (1) NG
P1_PCV2 67.5 13.0
P2_PCV1 69.1 14.6
Supply pump-B (2) OK
P2_PCV2 68.7 14.2
q Supply pump-B (2) might be defective when:

There is not a larger difference than 2 CA between standard value and the value when the connector (P1_PCV2) is dis-
connected. The supply pump-B (2) may be defective.
PCV Close Timing

P1_PCV1 67.5 14.0
Supply pump-A (1) OK
P1_PCV2 69.1 15.6
P2_PCV1 68.8 15.3
Supply pump-B (2) NG
P2_PCV2 53.4 0.1
q Supply pump-A (1) and supply pump-B (2) might be defective when:
NOTICE
There is not a larger difference than 2 CA between standard value and the value when the connector is discon-
nected. The supply pump -A (1) or -B (2) may be defective.
30-58 HD465-8, HD605-8

30 TEST AND ADJUST SUPPLY PUMP TEST
PCV Close Timing

P1_PCV1 67.5 7.1
Supply pump-A (1) NG
P1_PCV2 69.1 8.7
P2_PCV1 68.8 8.4
Supply pump-B (2) NG
P2_PCV2 67.9 7.5
REMARK
Failure codes and "TROUBLESHOOTING OF ENGINE (S MODE)" are as follows.
q Failure code [CA559]
q Failure code [CA2249]
q S mode "Engine cranks but no exhaust gas comes out"
q S mode "Engine startability is poor"
q S mode "Engine does not pick up smoothly"
q S mode "Fuel mixes into engine oil"
REMARK
Failure codes are shown because the test of the supply pump is performed while PCV connectors are disconnected. See "PRO-
CEDURE TO CERTIFY ABNORMALITY RECORD (ELECTRICAL SYSTEMS)", "SET AND OPERATE OF MACHINE MONI-
TOR" and delete all the abnormality records.
HD465-8, HD605-8 30-59

CYLINDER CUT-OUT MODE 30 TEST AND ADJUST
CYLINDER CUT-OUT MODE

The cylinder cutout mode is used to run the engine with the fuel injectors of one or more cylinders disabled electrically to reduce
the number of cylinders in operation. The function and effects of cylinder cutout mode are as follows.
q Cylinder cutout mode is used to find out a cylinder which does not output power correctly, or the combustion procedure is
incorrect.
q When a cylinder is cutout and the engine speed and output do not change from the normal operation (all-cylinder opera-
tion), that cylinder has a failure.
The possible failures are as follows.
q Compression gas leakage from cylinder head gasket area
q Defective injection
q Defective piston, piston ring or cylinder liner
q Defective valve mechanism (valve operating system)
q Defective electrical system
q Common rail fuel injection system controls the injector of each cylinder electronically. The cylinder cutout test performed
easily by the simple operations of the switches compared with the mechanical fuel injection system. The defective cylinder
can be found easily.
30-60 HD465-8, HD605-8

30 TEST AND ADJUST NO-INJECTION CRANKING
NO-INJECTION CRANKING
No-injection crank operation is to turn the engine while all the injector are disabled electrically. The function and effect of this
operation are as follows.
No-injection crank is performed to lubricate the engine parts and to protect them from failure. It is performed before the engine
is started after the machine or engine was stored for a long period.
HD465-8, HD605-8 30-61

CLEAN FUEL DOSER 30 TEST AND ADJUST
CLEAN FUEL DOSER

Tools to clean the fuel doser

A Commercially available Cloth 1
B Commercially available Diesel fuel - For cleaning
C Commercially available Nylon brush 1
k Install or remove the fuel doser after the exhaust manifold and pipe temperature decrease.
To perform the cleaning to troubleshoot fuel doser, refer to this section.
CLEAN FUEL DOSER
1. Remove fuel dosers (2) and (3). For details, see DISASSEMBLY
AND ASSEMBLY, "REMOVE AND INSTALL FUEL DOSER
ASSEMBLY".
NOTICE
q When cleaning the fuel doser in troubleshooting for
[CA****], clean fuel doser (2).
q When cleaning the fuel doser in troubleshooting for
[CB****], clean fuel doser (3).
REMARK
It is not necessary to disconnect the fuel hose (4) and the coolant
hose in this check.
2. Soak cloth A with sufficient volume of diesel fuel B. Push it
against the accumulated soot (a) at the fuel doser injection port
end for the diesel oil to remove the soot.
30-62 HD465-8, HD605-8

30 TEST AND ADJUST CLEAN FUEL DOSER
3. After diesel oil B cleans the soot (a), wipe off the soot with cloth
A.
4. Brush the injection port end to remove the soot in the injection
port with nylon brush C.
Eliminate soot completely from the injection port with nylon brush
C and cloth A.
NOTICE
q Use a nylon brush for cleaning. Do not use a wire brush
otherwise it may damage the injection port.
q Use diesel fuel to clean. Do not use other solvents.
Injection port end after you clean

Completely clean (no soot remains at injection port (b))
Not completely clean (soot remains at injection port (c))
After you finish the cleaning, assemble the machine. For details, see DISASSEMBLY AND ASSEMBLY, "REMOVE AND IN-
STALL FUEL DOSER ASSEMBLY".
NOTICE
q Use new mount bolts, gaskets, and heat insulator.
q After cleaning the fuel doser, make sure to reset the fuel doser information. For details, see "PROCEDURE TO OP-
ERATE THE TEST MENU (KDPF MEMORY RESET)".
After you install the fuel doser assembly, run the engine at low idle for approximately 3 minutes. Then stop the engine, and
examine the water and fuel circuits of the fuel doser for leakage.
HD465-8, HD605-8 30-63

PROGRAM INJECTOR TRIM CODE VALUE TO ENGINE CONTROLLER 30 TEST AND ADJUST
PROGRAM INJECTOR TRIM CODE VALUE TO ENGINE

CONTROLLER
Tools to program Trim code values of the injector and controller

A Commercially available Laptop computer 1 Windows® 8 (32 bit)
B Cu3886388 INSITE 1
C 795-799-5732 INLINE 5 Kit 1
Commercially available
D Cable (USB) 1
or 795-799-5742
E 795-799-5721 Cable 1
F 799-601-4510 Cable (12P) 1
NOTICE
If a defect (shutdown or disconnection) occurs in the computer or cable, there may be a serious error in the engine
controller. To avoid that, examine the connection of the cable and make sure it is correctly connected.
For the INSITE installation to the computer, insert the DVD-ROM software and follow the shown menus.
To connect INSITE to the engine controller, do not stop the power supply from the battery to the engine controller.
If the power supply is stopped, INSITE will disconnect.
Make sure that there is no replacement record of injectors and engine controllers in the maintenance note. If the replacement
record exists, note the information such as injector trim code values.
When the injector is replaced to troubleshoot, it is possible to write the data information to the engine controller by referring to
this section.
PROCEDURE TO PROGRAM INJECTOR TRIM CODE VALUE
1. Write the injector trim code values to maintenance note.
q When injector is replaced
Record the cylinder number of injector to be replaced and
trim code values programed on the new injector.
REMARK
Read the code on the top surface of the injector from left to
right, start with the top line.
30-64 HD465-8, HD605-8

30 TEST AND ADJUST PROGRAM INJECTOR TRIM CODE VALUE TO ENGINE CONTROLLER
q When engine controller is replaced

Program the injector trim code value programmed on the old
engine controller to the new engine controller.
a: Line of characters
b: QR code
REMARK
When the engine controller is replaced, there may be a dif-
ference in data recorded. The data sheet behind the control-
ler may differ from the information in the controller. This may
be because an injector or controller was previously replaced.
In this condition, use the trim code value contained in the
maintenance record information. Alternatively, import the
trim code value described on the top face of every injector installed on the cylinders, in the same way as you did in the
above when you replaced the injector.
2. When you replace an injector, clean the values on the trim code value sheet on the back of the engine controller.
1) Clean the former data characters of the replaced injector on the trim code value sheet that is provided on the back
of the controller. (Add line out.)
2) Note the former data of the replaced injector in the maintenance register.
3. Make sure that the start switch is turned to OFF position and the system operation lamp is off.
4. Connect the INLINE 5 kit C and cable F to computer A, and then
connect these to service connector (DL).
REMARK
q Be sure to turn OFF the start switch before you connect and
disconnect the computer.
q Service connector (DL) is installed behind the cover on the
rear of the operator's seat.
5. Start the computer.

6. Turn the start switch to ON position to supply current from the battery to the engine controller.
HD465-8, HD605-8 30-65

7. Double-click the icon shown in the figure.
8. Establish communication with the engine controller corre-

sponding to these procedures.
1) Make sure that display (a) is "INLINE5 USB (J1939)
Connection", and select "Connect to ECM".
2) Make sure that display (b) is "None", and select

"Connect".
When the illustration in connection condition display (e)
stops moment, the connection with the engine controller
is completed.
c: Connection process screen

d: Screen after the connection is complete (illustration
does not move)
e: Communication status is shown (illustration moves
during communication)
REMARK
While the illustration moves, communication with the en-
gine controller is in progress. Make sure that the illustra-
tion does not move at all, and then proceed to next step.
30-66 HD465-8, HD605-8

9. Program the data of injector trim code values corresponding to

this procedure.
1) Select screen (f) "Advanced ECM Data".
2) Select screen (g) "High-pressure Common Rail Injector

Setup".
3) Input new data to screen (h) "New Barcode".

REMARK
q When the injector is replaced, input the injector trim
code value of new injector. When the engine control-
ler is replaced, input the all injector trim code values
programed in the old engine controller to the new en-
gine controller.
q Input the trim code values referring the maintenance
note.
NOTICE
If the trim code values are not correctly programed,
an engine operation problem could occur.
10. After you input the injector trim code values to screen (j), select
screen (k) "Apply".
HD465-8, HD605-8 30-67

12. Select screen (m) "OK".
The data process screen is shown, and process is completed in

approximately 30 seconds.
13. After data program is completed, turn the start switch to ON position.
14. Select screen (n) "OK".
15. When the data program is completed, complete screen (p) is

shown. Select "OK" again.
30-68 HD465-8, HD605-8

16. When "success" is shown on screen (r), data writing is completed

correctly, then proceed to next step.
If screen (s) is shown, data writing is not completed correctly, re-

peat from injector trim code value input screen again.
REMARK
When the engine controller is replaced, input trim code value
may differ from the actual trim code value although there is no re-
placement record in the maintenance note. If the data is not pro-
gramed correctly, read the all injector trim code values directly
and input them.
17. Select screen (t) "Disconnect from ECM", and shut off the
communication with the engine controller.
After you complete the program, repair the machine.

Turn the start switch to OFF position, then turn the start switch to ON position again to make sure there are no errors present
on the machine monitor.
REMARK
If a failure code ([CA2765]: "Injector Trim Data Mismatch)" appears, follow troubleshoot procedure for that code.
HD465-8, HD605-8 30-69

PROGRAM ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CON-
TROLLER 30 TEST AND ADJUST
PROGRAM ASH IN SOOT ACCUMULATION CORRECTION TO

ENGINE CONTROLLER
k Make sure that there is no person or flammable material around the machine in the direction of the exhaust gas
flows.
q When you start the engine, ash contained in engine oil accumulates in KCSF and increases filter differential pressure.
q Since the difference between in and out filter pressure is used to calculate soot accumulation, an increase in quantity of
pressure difference makes it necessary to correct.
q Correction amount of filter differential pressure increased by ash is calculated in the engine controller as "Soot Correction
by Ash Influence".
q When engine controller is replaced with the new one, "Soot Correction by Ash Influence" becomes default value, 0 g/ℓ.
q When engine controller is replaced with the new one, perform applicable operation to obtain correct "Soot Correction by
Ash Influence".
PROCEDURE TO PROGRAM SOOT ASH ACCUMULATION CORRECTION TO ENGINE
CONTROLLER
Perform the applicable operation corresponding to these procedures.
q When only the engine controller is replaced.
Perform "Ash in Soot Accumulation Correction". For details, see "SETTING AND OPERATION OF MACHINE MONITOR".
q When both of engine controller and KCSF are replaced
The value of "Soot Correction by Ash Influence" and ash accumulated in KCSF become 0 g/ℓ, "Ash in Soot Accumulation
Correction" is not necessary.
Perform the applicable operation. For details, see TROUBLESHOOTING, "PRECAUTIONS FOR CLEANING AND RE-
PLACING KDPF (KCSF and KDOC)".
30-70 HD465-8, HD605-8

30 TEST AND ADJUST TEST TORQUE CONVERTER STALL SPEED
TEST TORQUE CONVERTER STALL SPEED

Be sure to measure the torque converter stall speed before you supply the machine to the owner, since the value changes in
these conditions.
q Change because of the engine condition
q Change because of the ambient pressure and ambient temperature
q Change because of to the auxiliary drive torque consumption
q Change because of the torque converters properties
q Change because of the difference in the test procedure
q Steering oil temperature: 45 to 55 °C
To perform the test to troubleshoot torque converter stall speed, refer to this section.
TEST TORQUE CONVERTER STALL SPEED
NOTICE
REMARK
in operation.
HD465-8, HD605-8 30-71

TEST TORQUE CONVERTER STALL SPEED 30 TEST AND ADJUST
6. With the brake pedal correctly depressed fully with your left foot,
shift the gear shift lever to D position and make sure that "F2" is
7. To stall the torque converter, depress the accelerator pedal grad-
ually to raise the torque converter oil temperature to between 70
to 80 °C.
8. When the torque converter oil temperature exceeds 90 ˚C, move
the accelerator pedal to low idle, and return the gear shift lever to
N position.
NOTICE
Do not move the gear shift lever while the accelerator pedal is depressed. Otherwise, a shift shock occurs and it
may cause damage or shorten the service life of the machine.
9. Operate the engine at a moderate speed until the torque converter oil temperature is less than 80 ˚C, and lift your right foot
off the accelerator pedal.
REMARK
Keep the gear shift lever in N position.
10. Repeat steps 6 to 9 to make sure the torque converter and transmission oil temperature is stable.
11. While you perform steps 6 to 7, measure the engine speed when the torque converter oil temperature is between 70 to 80
°C.
k Keep the brake pedal depress fully.
NOTICE
Be careful of the increase in the torque converter oil temperature during a stall test. Do not allow the torque con-
verter to become too hot.
REMARK
Test the torque converter stall speed 2 or 3 times.
For standard values, see STANDARD VALUE TABLE, "STANDARD VALUE TABLE FOR MACHINE".
30-72 HD465-8, HD605-8

30 TEST AND ADJUST RADIATOR FAN SPEED TEST
RADIATOR FAN SPEED TEST

Steering oil temperature: 45 to 55 ˚C
To perform the test to troubleshoot radiator fan speed, refer to this section.
RADIATOR FAN SPEED TEST
1. Set the fan mode to "2: Max". For details, see "SET AND
OPERATE OF MACHINE MONITOR", "PROCEDURE TO
ADJUST (FAN MODE FIXING)".
REMARK
When the fan mode is set to “2: Max”, fan speed of radiator fan
is set to the controlled maximum speed used for normal opera-
tion.

screen, and select "Self-define Monitoring".
REMARK
The content set in step 1 is held even after RETURN switch (12)
is pushed, until the start switch is turned to OFF position.
3. Display the following monitoring items. For details, see "PROCE-

DURE TO EXAMINE SELF-DEFINE MONITOR INFORMA-
TION".
q 01002: "Engine Speed"
q 32701: "S/T Oil Temperature"
q 10009: "Radiator Fan Speed "
4. Raise the steering oil temperature to between 45 and 55 ˚C.
HD465-8, HD605-8 30-73

RADIATOR FAN SPEED TEST 30 TEST AND ADJUST
5. Depress the accelerator pedal to the stroke end (high idle), and
measure "Radiator Fan Speed".
DARD VALUE TABLE FOR MACHINE".
30-74 HD465-8, HD605-8

30 TEST AND ADJUST TEST POWER TRAIN OIL PRESSURE
POWER TRAIN
TEST POWER TRAIN OIL PRESSURE
Tools to test power train oil pressure

D 07002-11023 O-ring 1
k Put the machine on level ground, set the parking brake switch to park (P), and stop the engine.
k Remove and install the test tools after the oil temperature is sufficiently lowered.
k To measure the oil pressure while you travel, be sure to secure large travel area , and operate the machine with
extreme care.
HD465-8, HD605-8 30-75

TEST POWER TRAIN OIL PRESSURE 30 TEST AND ADJUST
The drawing shows the oil pressure testing position.
30-76 HD465-8, HD605-8

Test power train oil pressure
No. Tested oil pressure name Pressure range (MPa)

1 Main relief pressure of power train 6
2 Main flow rate selector valve inlet pressure 6
3 Torque converter inlet pressure 2.5
4 Torque converter outlet pressure 2.5
5 Torque converter lockup clutch operating pressure 6
6 Transmission L clutch operating pressure 6
7 Transmission H clutch operating pressure 6
8 Transmission 1st clutch operating pressure 6
9 Transmission 2nd clutch operating pressure 6
10 Transmission 3rd clutch operating pressure 6
11 Transmission 4th clutch operation pressure 6
12 Transmission R clutch operating pressure 6
REMARK
The transmission lubrication oil pressure is omitted since it is replaced with the torque converter outlet pressure.
Gear shift lever position and travel gear speed during test of operating pressure of each clutch
Gear shift lever position Gear Clutch

R N D 6 5 4 3 2 L speed L H 1st 2nd 3rd 4th R
* ○ ○ ○ ○ ○ ○ F1 w ●
○ ○ ○ ○ ○ ○ F2 ● ●
○ ○ ○ ○ ○ F3 ● w
○ ○ ○ ○ F4 w ●
○ ○ ○ F5 w w
○ ○ F6 w ●
○ F7 w w
○ N
○ R w ●
REMARK
q ○ mark indicates the travel gear speed that is actuated at the respective gear shift lever position.
q * mark indicates the travel gear speed that is actuated when "F1" is set in "F1 Start at D Position Setting". Make sure that
"F2" is set before you perform this test.
q w mark and ● mark indicate the clutches that are actuated at each gear speed.
q ● mark indicates the travel gear speed when you measure the oil pressure for each clutch.
To perform the test to troubleshoot power train oil pressure, refer to this section.
HD465-8, HD605-8 30-77

POWER TRAIN OIL PRESSURE TEST

Procedure to test main relief pressure of power train
1. Lift the dump body and lock with body pivot pins.
REMARK
There is a mark of P4 on the oil pressure pickup plug (1).
3. Install the fitting D, and connect it to the gauge A1 of hydraulic
tester A.
3 Fitting D:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
REMARK
Gauge in digital hydraulic tester B can also be used in place of
gauge A1.
4. Put the body pivot pin back in the initial position and seat the
dump body.
5. Make sure each oil temperature is in the specified range.
6. Shift the gear shift lever to N position.
7. Measure the oil pressure when you depress the accelerator
pedal and the engine speed increases to 2000 rpm (target value).
3 Oil pressure pickup plug (1):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
Procedure to test main flow rate selector valve inlet pressure
REMARK
30-78 HD465-8, HD605-8


tester A.
3 Fitting D:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
REMARK
gauge A1.
dump body.

7. Measure the oil pressure when you depress the accelerator pedal and the engine speed increases to 2000 rpm (target
value), and when the accelerator pedal is not depressed (low idle).
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
Procedure to test torque converter inlet pressure
1. Refer to "POWER TRAIN OIL PRESSURE TEST" section to check that the power train main relief pressure is normal.
REMARK
3. Install the fitting D, and connect the gauge A2.

3 Fitting D:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
REMARK
gauge A2.
HD465-8, HD605-8 30-79


value).
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
Procedure to test torque converter outlet pressure
1. Refer to "POWER TRAIN OIL PRESSURE TEST" section to check that the power train main relief pressure is normal.

3 Fitting D:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
REMARK
gauge A2.

30-80 HD465-8, HD605-8

value).
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
Procedure to test torque converter lockup clutch operating pressure

tester A.
3 Fitting D:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
REMARK
gauge A1.
4. Put the body pivot pin back in the initial position and seat the dump body.
6. Set the parking brake switch to TRAVEL position.
7. Shift the gear shift lever to L position with the brake pedal
depressed.
8. Depress the accelerator pedal with the brake pedal released.

9. Measure the oil pressure when the engine speed gets to 2000
rpm (target value) and the torque converter lockup indicator lamp
illuminates.
k As the maximum speed increases to 11.5 km/h when the
gear speed is F1, operate the machine with extreme care
for the safety.
chine.
HD465-8, HD605-8 30-81


9.8 to 12.7 Nm {1.0 to 1.3 kgm}
30-82 HD465-8, HD605-8

Procedure to test transmission L clutch operating pressure


tester A.
3 Fitting D:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
REMARK
gauge A1.
4. Put the body pivot pin back in the initial position and seat the dump body.
7. Shift the gear shift lever to 2 position with the brake pedal
depressed.

rpm (target value) and "F2" is shown on the shift indicator.
for the safety.
chine.
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
HD465-8, HD605-8 30-83

Procedure to test transmission H clutch operating pressure


tester A.
3 Fitting D:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
REMARK
gauge A1.
dump body.
depressed.

for the safety.
chine.
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
30-84 HD465-8, HD605-8

Procedure to test transmission 1st clutch operating pressure


tester A.
3 Fitting D:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
REMARK
gauge A1.
dump body.
7. Shift the gear shift lever to L position with the brake pedal
depressed.
rpm (target value).
gear speed is F1, operate the machine with extreme care for the safety.
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
Procedure to test transmission 2nd clutch operating pressure
HD465-8, HD605-8 30-85


tester A.
3 Fitting D:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
REMARK
gauge A1.
dump body.
depressed.

for the safety.
chine.
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
Procedure to test transmission 3rd clutch operating pressure

30-86 HD465-8, HD605-8


tester A.
3 Fitting D:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
REMARK
gauge A1.
dump body.
depressed.

for the safety.
chine.
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
Procedure to test transmission 4th clutch operating pressure

HD465-8, HD605-8 30-87


tester A.
3 Fitting D:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
REMARK
gauge A1.
dump body.
depressed.

for the safety.
chine.
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
Procedure to test transmission R clutch operating pressure
30-88 HD465-8, HD605-8


tester A.
3 Fitting D:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
REMARK
gauge A1.
dump body.
7. Shift the gear shift lever to R position with the brake pedal
depressed.
rpm (target value).
gear speed is R1, operate the machine with extreme care for the safety.
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
HD465-8, HD605-8 30-89

ADJUST TRANSMISSION INPUT SHAFT SPEED SENSOR 30 TEST AND ADJUST
ADJUST TRANSMISSION INPUT SHAFT SPEED SENSOR

To perform the adjustment to troubleshoot transmission input shaft speed sensor, refer to this section.
ADJUST TRANSMISSION INPUT SPEED SENSOR
1. Remove the input shaft speed sensor (1) and make sure that
there is no metal attached or damage in the sensor edge part,
and then assemble lightly in the initial location.
2 Sensor threaded part:
Liquid gasket (LG-5)
REMARK
Connector number for the input shaft speed sensor (1) is N1.
2. Tighten the sensor (1) until the edge touches the tooth point of
gear (4) lightly.
3. Loosen the sensor (1) 1/2 to 1 turns from the position of step 2.
Clearance (a) of 0.75 to 1.5 mm appears between the edge of
sensor (1) and tooth point of gear (4).
4. While you hold the sensor (1), tighten the nut (5).
3 Nut (5):
49.0 to 68.6 Nm {5 to 7 kgm}
Refer to "CHECK AFTER ADJUSTMENT OF TRANSMISSION
SPEED SENSORS" and make sure that signals from the rotation
sensor are input normally.
30-90 HD465-8, HD605-8

30 TEST AND ADJUST ADJUST TRANSMISSION INTERMEDIATE SPEED SENSOR
ADJUST TRANSMISSION INTERMEDIATE SPEED SENSOR

To perform the adjustment to troubleshoot transmission intermediate shaft speed sensor, refer to this section.
ADJUST THE TRANSMISSION INTERMEDIATE SPEED SENSOR
1. Remove the intermediate shaft speed sensor (2) and make sure
that there is no metal attached or damage in the sensor edge
part, and then assemble lightly in the initial location.
REMARK
Connector number for the intermediate shaft speed sensor (2) is
N2.
gear (6) lightly.
Clearance (b) of 0.75 to 1.5 mm appears between the edge of
3 Nut (7):
49.0 to 68.6 Nm {5 to 7 kgm}
HD465-8, HD605-8 30-91

ADJUST TRANSMISSION OUTPUT SPEED SENSOR 30 TEST AND ADJUST
ADJUST TRANSMISSION OUTPUT SPEED SENSOR

To perform the adjustment to troubleshoot transmission output shaft speed sensor, refer to this section.
ADJUST TRANSMISSION OUTPUT SPEED SENSOR
1. Remove the output shaft speed sensor (3) and make sure that
there is no metal attached or damage in the sensor edge part,
and then assemble lightly in the initial location.
REMARK
Connector number for the output shaft speed sensor (3) is N3.
gear (8) lightly.
Clearance (c) of 0.75 to 1.5 mm appears between the edge of
3 Nut (9):
49.0 to 68.6 Nm {5 to 7 kgm}
30-92 HD465-8, HD605-8

30 TEST AND ADJUST CHECK AFTER ADJUSTMENT OF TRANSMISSION SPEED SENSORS
CHECK AFTER ADJUSTMENT OF TRANSMISSION SPEED

SENSORS
The shaft speed is measured by the speed sensor and viewed by the monitor function of the machine monitor.
When the speed sensor adjustment is performed, make sure that signals from the rotation sensor is input normally.
PROCEDURE TO CHECK AFTER ADJUSTMENT THE TRANSMISSION SPEED SEN-
SORS
2. Select the following monitoring items. For details, see "SET AND
Monitoring code: 31200 "T/M Input Shaft Speed"
Monitoring code: 31300 "T/M Intermediate Shaft Speed"
Monitoring code: 31400 "T/M Output Shaft Speed"
3. Operate the machine and make sure that the transmission shaft
speeds are shown.
HD465-8, HD605-8 30-93

MOVE A MACHINE WITH ELECTRICAL SYSTEM PROBLEMS 30 TEST AND ADJUST
MOVE A MACHINE WITH ELECTRICAL SYSTEM PROBLEMS

If a failure occurs in the electrical system of the engine control system or transmission control system, the engine may not start
or machine may not move off.
In this case, repair the engine electrical system or the transmission electrical system temporarily, and troubleshoot the problem
completely.
MOVE A MACHINE WITH ENGINE CONTROL SYSTEM PROBLEMS
Select the procedure for the movement problem corresponding to the flow chart to move the machine.
REMARK
For the procedure to examine the failure code, see the section of "SET AND OPERATE OF MACHINE MONITOR".
*1: If the engine will not start, the parking brake will not release. In such case, release the parking brake temporarily. For details,
see "RELEASE PARKING BRAKE MANUALLY".
PROCEDURE TO MOVE MACHINE WITH TRANSMISSION CONTROL SYSTEM PROB-
LEM
Examine the failure code, and select the procedure to move corresponding to the table to move the machine.
30-94 HD465-8, HD605-8

30 TEST AND ADJUST MOVE A MACHINE WITH ELECTRICAL SYSTEM PROBLEMS
REMARK
For the procedure to examine the failure code, see the section of "SET AND OPERATE OF MACHINE MONITOR".
Condition when Evacuation Lever position of moving-off gear speed

Failure code Remarks
a failure occurs procedure after evacuative operations
Occurrence Evacuation
1500L0 -
condition 2 procedure 2
15G0MW D to L: F2 gear speed
q Occurrence condition 1
Occurrence Evacuation The gear speed is fixed and is not
15H0MW D to L: F2 gear speed, R:R
condition 7 procedure 1 shifted from the gear speed fixed
Occurrence Evacuation when moving off again.
15J0MW D to L: F2 gear speed, R:R When the gear shift lever is
moved to N, the gear speed be-
Occurrence Evacuation comes neutral.
15K0MW D to L: F2 gear speed, R:R
condition 7 procedure 3 q Occurrence condition 2
Occurrence Evacuation The machine cannot move off
15L0MW D to L: F2 gear speed, R:R even by operation the gear shift
lever after stop the travel.
Occurrence Evacuation q Occurrence condition 3
15M0MW D to L: F2 gear speed, R:R
condition 7 procedure 3 The gear speed is changed to
Occurrence Evacuation neutral during travel.
15N0MW D to L: F2 gear speed, R:R q Occurrence condition 4
Even by operating the gear shift
Occurrence Evacuation lever after start of the engine, the
15SBL1 R:R
condition 7 procedure 1 gear speed fixed at neutral and
the machine cannot move off.
15SBMA D to L: F2 gear speed q Occurrence condition 5
The lever response becomes ab-
Occurrence Evacuation normal, and the gear shift lever
15SCL1 D to L: F2 gear speed, R:R
condition 7 procedure 1 does not work.
When operating the gear shift le-
15SCMA D to L: F2 gear speed, R:R ver, the gear speed is changed to
neutral.
Occurrence Evacuation q Occurrence condition 6
15SDL1 D to L: F2 gear speed, R:R
condition 7 procedure 1 The gear speed is fixed and is not
shifted from the gear speed fixed
Occurrence Evacuation when moving off again.
15SDMA D to L: F2 gear speed, R:R
condition 7 procedure 1 When the gear shift lever is
Occurrence Evacuation moved to N, the gear speed be-
15SEL1 D to L: F1 gear speed comes neutral but gear shift after
that cannot be made.
Occurrence Evacuation Occurrence condition 7
15SEMA D to L: F2 gear speed, R:R q
condition 7 procedure 1 Select the clutch that is available
Occurrence Evacuation for traveling, and fix the gear
15SFL1 D to L: F2 gear speed speed.
If the clutch that is available for
Occurrence Evacuation traveling can not be selected, the
15SFMA D to L: F1 gear speed, R:R
condition 7 procedure 1 gear speed becomes neutral.
Occurrence Evacuation When the gear shift lever is
15SGL1 D to L: F4 gear speed moved to N, the gear speed be-
comes neutral.
Occurrence Evacuation *1: Even when the machine is
15SGMA D to L: F2 gear speed, R:R
condition 7 procedure 1 recovered from a failure, the gear
Occurrence Evacuation speed is fixed at neutral until the
15SHL1 D to L: F6 gear speed gear shift lever is moved to N
temporarily.
15SHMA D to L: F2 gear speed, R:R
15SJMA D to L: F2 gear speed, R:R
HD465-8, HD605-8 30-95


Occurrence Evacuation Normal travel can be performed by
DAQOKK
condition 1 procedure 5 return to the normal display. (*1)
DAQ2KK
DAQ9KQ -
DAQRKR
DAQRMA D to L: F2 gear speed, R:R
DB2RKR D to L: F2 gear speed, R:R
DF10KA
DF10KB
DLF1KA D to L: F2 gear speed, R:R
DLF1LC D to L: F2 gear speed, R:R
DLF2KA D to L: F2 gear speed, R:R
DLF2LC D to L: F2 gear speed, R:R
DLT3KA D to L: F2 gear speed, R:R
DXH1KA D to L: F2 gear speed, R:R
DXH1KB D to L: F2 gear speed, R:R
DXH1KY D to L: F2 gear speed, R:R
30-96 HD465-8, HD605-8

30 TEST AND ADJUST MOVE A MACHINE WITH ELECTRICAL SYSTEM PROBLEMS

DXH4KY D to L: F1 gear speed
DXH7KA D to L: F2 gear speed
DXH7KB D to L: F2 gear speed
DXH7KY R:R
DXHHKA D to L: F2 gear speed, R:R
DXHHKB D to L: F2 gear speed, R:R
DXHHKY D to L: F6 gear speed
Moving procedure
q Moving procedure 1
1.Stop the travel and shift the gear shift lever to N position.
2.Operate the gear shift lever to move again.
REMARK
q Do not depress the accelerator pedal while you operate the gear shift lever.
q Gear shift lever: N position → D to L position, or N position → R position
Tow the machine.
REMARK
If the engine cannot be started, the parking brake cannot be released. In such case, release the parking brake temporarily.
For details, see "RELEASE PARKING BRAKE MANUALLY".
1.Stop the travel and shift the gear shift lever to N position.
2.Temporarily disconnect connector (A1: Male) and connector (A2: Female), connect them again, and then shift to the
move mode.
3.Operate the gear shift lever to move again.
REMARK
q Do not depress the accelerator pedal while you operate the gear shift lever.
q Gear shift lever: N position → D to L position, or N position → R position
q The move mode continues until you turn the start switch to OFF position.
HD465-8, HD605-8 30-97

q For details of the connector position, see TROUBLESHOOTING, "CONNECTORS LIST AND LAYOUT".
Examine the circuit breaker, fuse, T/M solenoid relay, solenoid power supply circuit, and GND. If they are normal, replace
the transmission controller.
Circuit breaker: FuB1 (No.62 - No.63) (105 A)
Fuse: BT2-No.10 (15 A)
REMARK
For details of the positions of the circuit breaker and fuse, see TROUBLESHOOTING, "FUSE LOCATION TABLE".
Examine the fuse unit, fuse, power supply circuit, and GND. If they are normal, replace the transmission controller.
Circuit breaker: FuB1 (No.62 - No.63) (105 A)
Fuse: Fuse box BT2-No.10 (15 A)
REMARK
For details of the positions of the circuit breaker and fuse, see TROUBLESHOOTING, "FUSE LOCATION TABLE".
Set the machine model selection again, and then set the option item again.
REMARK
q For details of the machine model selection settings, see "PROCEDURE TO SET WITH DEFAULT SETTING MENU
(MACHINE MODEL SELECT)".
q For details of the option settings, see "PROCEDURE TO SET WITH DEFAULT SETTING MENU (OPTION SELEC-
TION)".
If the fuse is normal as a result of the fuse test, replace the gear shift lever.
Fuse: Fuse box BT2-No.6 (10 A)
REMARK
For details of the fuse position, see TROUBLESHOOTING, "FUSE LOCATION TABLE".
30-98 HD465-8, HD605-8

30 TEST AND ADJUST TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE
STEERING SYSTEM
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE
Tools to test and adjust steering oil pressure

A
D 07002-11023 O-ring 1
k When you measure with the dump body is lifted, make sure to put the dump lever back to HOLD position and put
the dump lever lock knob to the locked position. Make sure to engage the body pivot pins.
To perform the test to troubleshoot steering circuit oil pressure, refer to this section.
TEST STEERING CIRCUIT OIL PRESSURE WITH THE MACHINE MONITOR
2. For the machine equipped with machine lock-out function, make sure that the machine lock-out operation switch is set to
OFF position.
REMARK
If the machine lockout operation switch is set to ON position, oil does not flow to the steering circuit and oil pressure test
cannot be performed.
3. Make sure the steering oil temperature is in the specified range.
4. Set the S/T pump swash plate to "1: Max". For details, see "SET
AND OPERATE OF MACHINE MONITOR", "PROCEDURE TO
ADJUST (S/T PUMP SWASH PLATE FIXING)".
5. Operate the steering to either direction to full travel end.
6. Depress the accelerator pedal to travel end (high idle).
7. Continue to turn the steering wheel to the left or right. Measure
the oil pressure when the relief valve operates (the maximum
pressure as the steering operation).
TEST STEERING CIRCUIT PRESSURE WITH TEST TOOLS
1. Lift the body and set the dump lever to the hold position.
2. Set the dump lever lock knob to LOCK position.
3. Engage the body pivot pins and stop the engine.
4. Remove the hydraulic tank oil filling cap to release remaining pressure inside the circuit.
HD465-8, HD605-8 30-99

TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE 30 TEST AND ADJUST
REMARK
The plug (2) for the machine with machine lock-out is on the right
side of the machine.
6. Install the fitting C, and connect the gauge A1.
REMARK
gauge A1.
9. For the machine equipped with machine lock-out function, make
sure that the machine lock-out operation switch is set to OFF
position.
REMARK
If the machine lockout operation switch is set to ON position, oil
does not flow to the steering circuit and oil pressure test cannot
be performed.
30-100 HD465-8, HD605-8

30 TEST AND ADJUST TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE
13. Continue to turn the steering wheel to the left or right. Measure the oil pressure when the relief valve operates (the
maximum pressure as the steering operation).
NOTICE
Replace the body pivot pin to the initial position after you lower the dump body.
PROCEDURE FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE
If the relief pressure in the steering circuit is not normal, adjust the
relief valve (1) on the demand valve.
1. Remove the cap (2).

2. Loosen the locknut (3).
3. Turn the adjustment screw (4) to adjust oil pressure.
q Turn the adjustment screw (4) to the right to raise the pres-
sure.
q Turn the adjustment screw (4) to the left to lower the pres-
sure.
q Pressure adjustment for 1 turn of adjustment screw (4): 2.43
MPa {24.8 kg/cm2}
4. Hold the adjustment screw (4) with a driver and tighten the
locknut (3).
3 Locknut (3):
11.8 to 4.7 Nm {1.2 to 1.5 kgm}
After you finish the adjustment, measure the steering circuit oil pressure again.
HD465-8, HD605-8 30-101

TEST SUPPLY PRESSURE OF ORBITROL VALVE 30 TEST AND ADJUST
TEST SUPPLY PRESSURE OF ORBITROL VALVE

Tools to test orbitrol valve pressure

A
D 07002-11023 O-ring 1
To perform the test to troubleshoot orbitrol valve supply pressure to perform troubleshooting, refer to this section.
PROCEDURE TO TEST SUPPLY PRESSURE OF ORBITROL VALVE
1. Remove the hydraulic tank oil filling cap to release remaining
pressure inside the circuit.
30-102 HD465-8, HD605-8

30 TEST AND ADJUST TEST SUPPLY PRESSURE OF ORBITROL VALVE
REMARK
gauge A1.

OFF position.
REMARK
the oil pressure when the steering relief valve operates (the
maximum pressure as the steering operation).
HD465-8, HD605-8 30-103

TEST STEERING CYLINDER PRESSURE 30 TEST AND ADJUST
TEST STEERING CYLINDER PRESSURE

Tools to test steering cylinder pressure

2 799-101-5160 Fitting 1 Size: R1/8
C 799-401-3200 Adapter 2 Size: 03
To perform the test to troubleshoot steering cylinder source pressure, refer to this section.
PROCEDURE TO TEST STEERING CYLINDER PRESSURE
2. Disconnect the hoses (1) and (2).
REMARK
q Measure the pressure when the steering wheel is kept turned
to the left: Hose (1)
q Measure the pressure when the steering wheel is kept turned
to the right: Hose (2)
3. Attach the adapter C to connect the disconnected hoses.

4. Install the fitting A2 to the adapter C, and connect it to the gauge
A1.
REMARK
gauge A1.
position.
REMARK
30-104 HD465-8, HD605-8

30 TEST AND ADJUST TEST STEERING CYLINDER PRESSURE
the oil pressure when the relief valve operates (the maximum
pressure as the steering operation).
HD465-8, HD605-8 30-105

BLEED AIR FROM STEERING CYLINDER CIRCUIT 30 TEST AND ADJUST
BLEED AIR FROM STEERING CYLINDER CIRCUIT

k Make sure that the hydraulic oil is at the specified level.
k If the orbitrol valve or steering cylinder were removed and installed, bleed air from the steering circuit correspond-
ing to these procedures.
To perform the air bleed from steering cylinder circuit to troubleshoot, refer to this section.
PROCEDURE TO BLEED AIR FROM STEERING CYLINDER CIRCUIT
1. Start the engine, and run at low idle for approximately 5 minutes.
2. Operate the steering wheel left and right not to travel end of the steering cylinder at the speed of 30 rpm (1 rotation for each
2 seconds).
NOTICE
To prevent damage to the piston seal, do not move the steering cylinder to the stroke end.
3. Repeat above step 2., 10 times.
4. Operate the steering wheel left and right to travel end of the steering cylinder at the speed of 30 rpm (1 rotation for each 2
seconds).
5. Operate the steering wheel left and right to travel end of the steering cylinder as fast as possible.
REMARK
During the operation, when the steering cylinder comes to travel end, operate to the other side immediately. (Continuous
operation)
6. Repeat above step 5., 10 times.
30-106 HD465-8, HD605-8

30 TEST AND ADJUST RELEASE PRESSURE IN BRAKE ACCUMULATOR CIRCUIT
BRAKE SYSTEM
RELEASE PRESSURE IN BRAKE ACCUMULATOR CIRCUIT
To perform the remaining pressure release from the brake accumulator circuit to troubleshoot, refer to this section.
RELEASE THE PRESSURE IN BRAKE ACCUMULATOR CIRCUIT
Before you disconnect these brake accumulator circuits, release the pressure in the circuit.
q Between accumulator charge valve and brake accumulator
q Between accumulator charge valve and parking brake emergency release valve
q Between brake accumulator and brake valve
Depress the brake pedal minimum 100 times to release the pressure in the brake accumulator circuit.
HD465-8, HD605-8 30-107

TEST WHEEL BRAKE OIL PRESSURE 30 TEST AND ADJUST
TEST WHEEL BRAKE OIL PRESSURE

Tools to test wheel brake oil pressure

A
2 799-101-5160 Fitting 1
3 790-301-1530 Elbow 1
To perform the test to troubleshoot wheel brake, refer to this section.
FRONT BRAKE ACTUATION PRESSURE TEST
Perform the pressure tests on the left and right front brakes.
1. Depress the brake pedal minimum 100 times to release the pressure in the brake accumulator circuit.
2. Remove the air bleeder (1).
3. Install the brake test kit C, and connect the gauge A1.
REMARK
gauge A1.
5. See "BLEED AIR FROM BRAKE CIRCUIT" to bleed air from the
brake circuit.
REMARK
Perform the air bleed procedure using the air bleeder of the brake
test kit C.
30-108 HD465-8, HD605-8

30 TEST AND ADJUST TEST WHEEL BRAKE OIL PRESSURE
6. Make sure that front brake off switch (2) is set to OFF.
REMARK
If front brake off switch (2) is set to ON, the front brake cannot op-
erate and oil pressure test will not be performed.
7. Operate the engine for a few minutes without depressing the accelerator pedal (low idling) and stop the engine after accu-
mulating oil into the accumulator.
REMARK
When the brake oil pressure caution lamp turns OFF, oil pressure is accumulated in the accumulator.
8. Measure the oil pressure with the brake pedal depressed to travel end.
k See "BLEED AIR FROM BRAKE CIRCUIT", and make sure to bleed air from the brake circuit.
REAR BRAKE ACTUATION PRESSURE TEST
Perform the pressure tests on the left and right rear brakes.
3. Install the brake test kit C using elbow A3.

brake circuit.
REMARK
q Perform the air bleed procedure using the air bleeder of the
brake test kit C.
q The figure shows the connection of the air bleeder part of the
parking brake. The same connection of test equipment also
applied to the rear brake.
HD465-8, HD605-8 30-109

TEST WHEEL BRAKE OIL PRESSURE 30 TEST AND ADJUST
6. Connect the gauge A1.
REMARK
gauge A1.
7. Operate the engine for a few minutes without depressing the
accelerator pedal (low idling) and stop the engine after accumu-
lating oil into the accumulator.
REMARK
When the brake oil pressure caution lamp turns OFF, oil pres-
sure is accumulated in the accumulator.
8. Measure the oil pressure with the brake pedal depressed to travel end.
RETARDER BRAKE PRESSURE TEST
Perform the pressure tests on the left and right retarder brakes.

brake circuit.
REMARK
test kit C.
REMARK
gauge A1.
7. Operate the engine for a few minutes without depressing the accelerator pedal (low idling) and stop the engine after accu-
mulating oil into the accumulator.
30-110 HD465-8, HD605-8

30 TEST AND ADJUST TEST WHEEL BRAKE OIL PRESSURE
REMARK
When the brake oil pressure caution lamp turns OFF, oil pressure is accumulated in the accumulator.
8. Measure the oil pressure with the retarder control lever fully pulled toward the operator.
RETARDER BRAKE ACTUATION PRESSURE TEST (FOR MACHINE WITH KTCS)

Perform the pressure tests on the left and right retarder brakes.

brake circuit.
REMARK
test kit C.
REMARK
gauge A1.
7. Fix the KTCS valve. For details, see "SET AND OPERATE OF
MACHINE MONITOR", "PROCEDURE TO ADJUST WITH
ADJUSTMENT MENU (KTCS VALVE SETTING)".
REMARK
q When the KTCS valve is set, "1" is shown in (a), and KTCS
will be in this condition of operation.
q The operation condition of KTCS is held until the display
goes to normal.
8. Measure the oil pressure with KTCS operating.
HD465-8, HD605-8 30-111

TEST AND ADJUST BRAKE ACCUMULATOR PRESSURE 30 TEST AND ADJUST
TEST AND ADJUST BRAKE ACCUMULATOR PRESSURE

Tools to test and adjust brake accumulator charge pressure

2 799-101-5160 Fitting 2 Size: R1/8
C 799-401-3200 Adapter 2 Size: 03
k Stop the engine and depress the brake pedal minimum 100 times to release the pressure in the accumulator cir-
cuit.
To perform the test and adjustment to troubleshoot brake accumulator pressure, refer to this section.
MEASURE BRAKE ACCUMULATOR PRESSURE USING THE MONITOR
1. Display the following monitoring items. For details, see "SET
EXAMINE SELF-DEFINE MONITOR INFORMATION".
Monitoring code: 35500 "Accumulator Oil Pressure Sensor
(Front)"
Monitoring code: 35501 "Accumulator Oil Pressure Sensor
(Rear)"
4. Depress the accelerator pedal to travel end and hold it.
5. Measure the cut-in pressure.
1) Repeat the "Depression" and "Release" operations of the brake pedal to gradually decrease the oil pressure in the
accumulator.
2) Measure the oil pressure when the low pressure side of the indicated value of the accumulator oil pressure (front
or rear) turns from falling to rising.
6. Measure the cut-out pressure.
Measure the oil pressure when the oil pressure rises from the cut-in pressure and the indicated value of the accumulator
oil pressure (front or rear) stops at the upper limit.
TEST BRAKE ACCUMULATOR PRESSURE WITH TEST TOOLS
30-112 HD465-8, HD605-8

30 TEST AND ADJUST TEST AND ADJUST BRAKE ACCUMULATOR PRESSURE
2. Remove the cover (1).
3. Disconnect the hoses (3) and (4) of accumulator (2).
REMARK
q Hose (3) is on the rear brake side.
q Hose (4) is on the front brake side.
4. Install the adapter C, and connect the hoses (3) and (4).
REMARK
gauge A1.
7. Select and display "Pre-defined Monitoring" (01/28) or following
monitoring items. For details, see "SET AND OPERATE OF
MACHINE MONITOR".
9. Depress the accelerator pedal to travel end and hold it.
10. Measure the cut-in pressure.
1) Repeat the "Depression" and "Release" operations of the
brake pedal to gradually decrease the oil pressure in the
accumulator.
2) Measure the oil pressure when the low pressure side of
the indicated value of the accumulator oil pressure (front
or rear) turns from falling to rising.
For standard values, see STANDARD VALUE TABLE,
"STANDARD VALUE TABLE FOR MACHINE".
11. Measure the cut-out pressure.
Measure the oil pressure when the oil pressure rises from the
cut-in pressure and the indicated value of the accumulator oil
pressure (front or rear) stops at the upper limit.
HD465-8, HD605-8 30-113

TEST AND ADJUST BRAKE ACCUMULATOR PRESSURE 30 TEST AND ADJUST
ADJUST BRAKE ACCUMULATOR PRESSURE

When the accumulator charge cut-out pressure is adjusted, the cut-in pressure changes in proportion to the valve area.
Loosen the locknut (2) on the accumulator charge valve while you
hold the adjustment screw (1), and turn the adjustment screw (1) to
adjust the pressure.
REMARK
Turn the adjustment screw (1) to the right to raise the pressure or
turn it to the left to lower the pressure.
3 Locknut (2):
10.2 Nm {1 kgm}
After adjustment, check the accumulator charge cut-in pressure and cut-out pressure again. For details, see "MEASURE
BRAKE ACCUMULATOR PRESSURE USING THE MONITOR".
30-114 HD465-8, HD605-8

TEST NITROGEN GAS PRESSURE IN BRAKE ACCUMULATOR AND CHARGE
30 TEST AND ADJUST NITROGEN GAS
TEST NITROGEN GAS PRESSURE IN BRAKE ACCUMULATOR

AND CHARGE NITROGEN GAS
According to the following, test nitrogen gas pressure in brake accumulator and charge nitrogen gas if it is insufficent pressure.
Tools to test nitrogen gas pressure in brake accumulator and charge nitrogen gas
Symbol Part No. Part name Q'ty Applicable standard

- 792-610-1703 Gas charging tool 1
A 1 792-610-2310 Extension 1
2 792-610-1260 Nipple (for Japan) 1 Size: W22-14 x W23-14
B 792-610-1270 Hose 1
C 792-610-2410 Bushing 1
D 792-610-1400 Regulator 1
792-610-1310 Nipple (for Russia) 1 GOST
792-610-1320 Nipple (for USA) 1 CGA No. 351
792-610-1330 Nipple (for USA) 1 ASA B-571-1965
E
DIN 477-1963
792-610-1350 Nipple (for Germany) 1 NEN 3268-1966
SIS-SMS2235/2238
792-610-1360 Nipple (for UK) 1 BS 341Part1-1962
Commercially
available
k Put on protection safety equipment, goggles, leather gloves and clothing to prevent nitrogen gas leak from your
skin. Perform this work on the up wind side as much as possible.
k When you use nitrogen gas in a small work area or in an unsatisfactory ventilated location, ventilate the area, and
observe the Safety and Health laws.
k The accumulator is pressurized with high-pressure nitrogen gas, and incorrect operation may cause an explosion
which would cause serious injury or death. When you handle, always observe these cautions.
q Do not bring open flame near or discard it in fire.
q Do not perform drilling, welding or cut with open flame.
q Do not hit, drop, or apply it to any external force.
q When disposing of the accumulator, use the gas charging tool A outdoors to discharge the nitrogen gas in the accumu-
lator little by little.
q Before you remove and take the assembly apart, be sure to lower the gas pressure to the ambient pressure.
q Be sure to only pressurize with nitrogen.
q Do not pressurize with explosive gas.
q Always use these procedures when you handle an accumulator.
HD465-8, HD605-8 30-115

NITROGEN GAS 30 TEST AND ADJUST
TEST NITROGEN GAS PRESSURE IN BRAKE ACCUMULATOR(FRONT)

You can test a single accumulator.
REMARK
Locations of accumulators for each brake are as follows.
(10): Parking brake accumulator
(11): Rear brake accumulator
(12): Front brake accumulator
1. Release the remaining pressure in the accumulator circuit. For details, see "RELEASE PRESSURE IN BRAKE ACCUMU-
LATOR CIRCUIT".
2. Remove the plug (2) and cap (3) from accumulator (1).
3. Connect the gas charging tool A to gas valve (4) of accumulator
(1) according to the following procedure.
1) Install the extension A1 which is attached to the gas

charging tool A to the gas valve (4).
2) Turn the handle (a) of the gas charging tool A fully to the
let (Between accumulator (1) and gas charging tool A:
Close). Turn the handle (b) fully to the right, and make it
closed.
REMARK
q The gas does not leak from the hose connection to
the atmosphere, since the valve (5) on the hose con-
nection side of the gas charging tool A is a check
valve (one way).
q The valve is closed by turning the handle (a) counter-
clockwise. The valve is open by turning the handle (a)
clockwise (Between charge valve and accumulator:
Open).
q The handle (a) is a screw-in type to open the valve.
30-116 HD465-8, HD605-8

q The valve is open (open to the atmosphere) by turning the handle (b) to the left (counterclockwise). The valve
is closed (close to the atmosphere) by turning the handle (b) to the right (clockwise).
q The handle (b) is a screw-in type to close the valve.
3) Connect the gas charging tool A to the the extension A1.
4) Put the cover to the valve (5) so that no rain, snow, sand, or dust enters.
4. Slowly turn the handle (a) of gas charging tool A clockwise and read the value of the gauge.
NOTICE
Do not turn the handle (a) more than 1.5 turns after the charge gas pressure is shown. Gas valve (4) may break.
REMARK
Make sure that gas does not leak.
1) The nitrogen gas pressure varies with the ambient temperature at the time you measure it. Refer to the table 1 below
to measure pressure.
REMARK
Specified gas pressure = Standard gas pressure x ((273 + t)/(273 + 20))
q All values in the formula are ˚C.
q t: Gas temperature in testing (it can be considered as ambient temperature)
Table 1: Nitrogen gas pressure table
Ambient temperature (t) Gas pressure

Remarks
˚C MPa kg/cm2
15 10.52 107.1
16 10.55 107.5
17 10.59 107.9
18 10.63 108.3
19 10.66 108.6
Standard temperature
20 10.70 109.0
Standard gas pressure
21 10.74 109.4
22 10.77 109.7
23 10.81 110.1
24 10.85 110.5
25 10.88 110.9
26 10.92 111.2
27 10.96 111.6
28 10.99 112.0
29 11.03 112.3
30 11.07 112.7
31 11.10 113.1
32 11.14 113.5
33 11.17 113.8
34 11.21 114.2
35 11.25 114.6
36 11.28 115.0
HD465-8, HD605-8 30-117


Remarks
˚C MPa kg/cm2
37 11.32 115.3
38 11.36 115.7
39 11.39 116.1
40 11.43 116.4
41 11.47 116.8
42 11.50 117.2
43 11.54 117.6
44 11.58 117.9
45 11.61 118.3
REMARK
q Adjust the gas pressure by proceeding to the step 5 if the gas pressure is too high when comparing the gas pressure
shown by the gauge and the specified gas pressure shown in Table 1.
q Proceed to the step 6 and adjust the gas pressure by referring to “METHOD FOR CHARGING NITROGEN GAS IN
BRAKE ACCUMULATOR” if the gas pressure is too low when comparing the gas pressure shown by the gauge and
the specified gas pressure shown in Table 1.
q If the gas pressure is correct, proceed to the step 7.
5. When reducing the nitrogen gas pressure in the accumulator after testing the nitrogen gas pressure in the accumulator
REMARK
Initial state: The handle (a) is open.
1) Turn the handle (b) counterclockwise slowly to discharge the nitrogen gas gradually from the thread part of the handle
(b) until the gauge of the gas charging tool A indicates that the pressure is the specified pressure shown in the Table
1, and close the valve by turning the handle (b) clockwise to adjust the nitrogen gas pressure in the accumulator (1).
2) Perform the adjustment according to the procedure in Step 7 or after.
6. When charging the nitrogen gas pressure in the accumulator after testing the nitrogen gas pressure in the accumulator
1) Turn the handle (a) to the left until it stops, and close the valve.
2) Turn the handle (b) counterclockwise gradually, and discharge the nitrogen gas remaining in gas charging tool A, and
let it open state. (Between handle (b) and atmosphere: Open for bleeding air from the hose)
3) Proceed to step 3. 5) of “METHOD FOR CHARGING NITROGEN GAS IN BRAKE ACCUMULATOR” and after, charge
the nitrogen gas in the accumulator to adjust the gas pressure.
7. Turn the handle (a) to the left until it stops, and close the valve.
8. Remove the gas charging tool A from accumulator (1) according to the following procedure, and restore the machine.
1) Turn the handle (b) counterclockwise to open the valve, and
discharge the nitrogen gas remaining in gas charging tool A
from the thread part of the handle (b).
2) Remove the gas charging tool A.
3) Remove the extension A1.
30-118 HD465-8, HD605-8

9. Apply soapy water to gas valve (4) of the accumulator, and check
that the nitrogen gas is not leaked.
10. Install the cap (3) and plug (2) to accumulator (1).
3 Plug (2):
73.5 to 98.0 Nm {7.5 to 10.0 kgm}
HD465-8, HD605-8 30-119

TEST NITROGEN GAS PRESSURE IN BRAKE ACCUMULATOR (REAR BRAKE AND

PARKING BRAKE)
You can test a single accumulator.
REMARK
Locations of accumulators for each brake are as follows.
(10): Parking brake accumulator
(11): Rear brake accumulator
(12): Front brake accumulator
LATOR CIRCUIT".
3. Connect the gas charging tool A to gas valve (4) of accumulator
(1) according to the following procedure.
1) Install the extension A1 which is attached to the gas

charging tool A to the gas valve (4).
2) Turn the handle (a) of the gas charging tool A fully to the
let (Between accumulator (1) and gas charging tool A:
Close). Turn the handle (b) fully to the right, and make it
closed.
REMARK
q The gas does not leak from the hose connection to
the atmosphere, since the valve (5) on the hose con-
nection side of the gas charging tool A is a check
valve (one way).
Open).
30-120 HD465-8, HD605-8

q The valve is open (open to the atmosphere) by turning the handle (b) to the left (counterclockwise). The valve
is closed (close to the atmosphere) by turning the handle (b) to the right (clockwise).
4) Put the cover to the valve (5) so that no rain, snow, sand, or dust enters.
4. Slowly turn the handle (a) of gas charging tool A clockwise and read the value of the gauge.
NOTICE
Do not turn the handle (a) more than 1.5 turns after the charge gas pressure is shown. Gas valve (4) may break.
REMARK
Make sure that gas does not leak.
1) The nitrogen gas pressure varies with the ambient temperature at the time you measure it. Refer to the table 1 below
to measure pressure.
REMARK
q All values in the formula are ˚C.
q t: Gas temperature in testing (it can be considered as ambient temperature)
Table 1: Nitrogen gas pressure table

Remarks
˚C MPa kg/cm2
15 6.09 61.9
16 6.12 62.1
17 6.14 62.4
18 6.16 62.6
19 6.18 62.8
20 6.20 63.0
21 6.22 63.2
22 6.24 63.4
23 6.26 63.6
24 6.28 63.9
25 6.31 64.1
26 6.33 64.3
27 6.35 64.5
28 6.37 64.7
29 6.39 64.9
30 6.41 65.2
31 6.43 65.4
32 6.45 65.6
33 6.48 65.8
34 6.50 66.0
35 6.52 66.2
36 6.54 66.4
HD465-8, HD605-8 30-121


Remarks
˚C MPa kg/cm2
37 6.56 66.7
38 6.58 66.9
39 6.60 67.1
40 6.62 67.3
41 6.64 67.5
42 6.67 67.7
43 6.69 67.9
44 6.71 68.2
45 6.73 68.4
REMARK
q Adjust the gas pressure by proceeding to the step 5 if the gas pressure is too high when comparing the gas pressure
shown by the gauge and the specified gas pressure shown in Table 1.
q Proceed to the step 6 and adjust the gas pressure by referring to “METHOD FOR CHARGING NITROGEN GAS IN
BRAKE ACCUMULATOR” if the gas pressure is too low when comparing the gas pressure shown by the gauge and
the specified gas pressure shown in Table 1.
q If the gas pressure is correct, proceed to the step 7.
5. When reducing the nitrogen gas pressure in the accumulator after testing the nitrogen gas pressure in the accumulator
REMARK
Initial state: The handle (a) is open.
1) Turn the handle (b) counterclockwise slowly to discharge the nitrogen gas gradually from the thread part of the handle
(b) until the gauge of the gas charging tool A indicates that the pressure is the specified pressure shown in the Table
1, and close the valve by turning the handle (b) clockwise to adjust the nitrogen gas pressure in the accumulator (1).
2) Perform the adjustment according to the procedure in Step 7 or after.
6. When charging the nitrogen gas pressure in the accumulator after testing the nitrogen gas pressure in the accumulator
1) Turn the handle (a) to the left until it stops, and close the valve.
2) Turn the handle (b) counterclockwise gradually, and discharge the nitrogen gas remaining in gas charging tool A, and
let it open state. (Between handle (b) and atmosphere: Open for bleeding air from the hose)
3) Proceed to step 3. 5) of “METHOD FOR CHARGING NITROGEN GAS IN BRAKE ACCUMULATOR” and after, charge
the nitrogen gas in the accumulator to adjust the gas pressure.
7. Turn the handle (a) to the left until it stops, and close the valve.
8. Remove the gas charging tool A from accumulator (1) according to the following procedure, and restore the machine.
1) Turn the handle (b) counterclockwise to open the valve, and
discharge the nitrogen gas remaining in gas charging tool A
from the thread part of the handle (b).
2) Remove the gas charging tool A.
3) Remove the extension A1.
30-122 HD465-8, HD605-8

3 Plug (2):
73.5 to 98.0 Nm {7.5 to 10.0 kgm}
HD465-8, HD605-8 30-123

METHOD FOR CHARGING NITROGEN GAS IN BRAKE ACCUMULATOR

It is possible to pressurize one accumulator at a time.
LATOR CIRCUIT".
3. Connect the gas charging tool A and nitrogen gas cylinder C to

gas valve (4) of accumulator (1) according to the following proce-
dure.
1) Turn the handle (a) of gas charging tool A counterclock-
wise until it stops. (Between accumulator (1) and gas
charging tool A: Close)
REMARK
Open).
2) Turn the handle (b) counterclockwise for opening.
(Between handle (b) and atmosphere: Open for bleeding
air from the hose)
REMARK
q The valve is open (open to the atmosphere) by turn-
ing the handle (b) to the left (counterclockwise).
The valve is closed (close to the atmosphere) by turn-
ing the handle (b) to the right (clockwise).
3) Install the extension A1 attached to gas charging tool A

to gas valve (4) of accumulator (1).
5) Connect the bushing C to the gas charging tool A.
6) Turn the handle (c) of the regulator D fully counterclock-
wise until it stops. Connect the regulator D to the nitrogen
gas cylinder F.
REMARK
q Connect the regulator D by using another nipple E
depending on the specification of the nitrogen gas
cylinder.
30-124 HD465-8, HD605-8

q The regulator is closed (stops discharging the gas) by turning the handle (c) counterclockwise. The regulator is
open (discharging the gas) by turning the handle (c) clockwise.
q The handle (c) is a screw-in type to open the regulator.
7) Connect the hose B to the bushing C and the regulator D.
4. Bleed air from the hose according to the following procedure.
1) Open the valve (d) of the nitrogen gas cylinder F until the
pressure on the cylinder side of the regulator D is approx-
imately 7 MPa {70 kg/cm2}.
2) Set the pressure on the hose side of the regulator D
approximately 0.19 to 0.29 MPa {2 to 3 kg/cm2} by slightly
turning the handle (c) clockwise. When the nitrogen gas
starts discharged from the thread part of the handle (b),
close the valve by turning the handle (b) clockwise.
3) Turn the handle (c) counterclockwise to close the valve of
the regulator.
5. Charge the nitrogen gas to the accumulator according to the
following procedure.
REMARK
The valve (d) is kept open from the step 4.1.
1) Turn the handle (a) clockwise slowly, and stop turning it
in a light response.
NOTICE
Do not turn handle (a) excessively, otherwise it damages the accumulator valve core and gas may leak. Op-
erate handle (a) carefully.
2) Turn the handle (a) clockwise slowly to open the valve of the regulator D gradually, and charge the nitrogen gas to
the accumulator until the pressure gauge is the specified pressure shown in the Table 1 or Table 2.
REMARK
Turn the handle (c) sometimes during the work to close the valve of the regulator D so that the pressure is stable.
Check the nitrogen gas pressure of the accumulator (1) by using the gauge of the gas charging tool A.
3) The gas pressure varies with the temperature at the measurement. See the Table 1 or Table 2 shown below and
check the gas pressure.
REMARK
q All values in the formula are °C.
q t: Gas temperature in charging (it can be regarded as ambient temperature)
Table 1: Charging nitrogen gas pressure table (For front brake accumulator)

Remarks
˚C MPa kg/cm2
15 10.52 107.1
16 10.55 107.5
17 10.59 107.9
18 10.63 108.3
19 10.66 108.6
20 10.70 109.0
HD465-8, HD605-8 30-125


Remarks
˚C MPa kg/cm2
21 10.74 109.4
22 10.77 109.7
23 10.81 110.1
24 10.85 110.5
25 10.88 110.9
26 10.92 111.2
27 10.96 111.6
28 10.99 112.0
29 11.03 112.3
30 11.07 112.7
31 11.10 113.1
32 11.14 113.5
33 11.17 113.8
34 11.21 114.2
35 11.25 114.6
36 11.28 115.0
37 11.32 115.3
38 11.36 115.7
39 11.39 116.1
40 11.43 116.4
41 11.47 116.8
42 11.50 117.2
43 11.54 117.6
44 11.58 117.9
45 11.61 118.3
Table 2: Charging nitrogen gas pressure table (For rear brake accumulator and parking brake accumulator )

Remarks
˚C MPa kg/cm 2
15 6.09 61.9
16 6.12 62.1
17 6.14 62.4
18 6.16 62.6
19 6.18 62.8
20 6.20 63.0
21 6.22 63.2
22 6.24 63.4
30-126 HD465-8, HD605-8


Remarks
˚C MPa kg/cm2
23 6.26 63.6
24 6.28 63.9
25 6.31 64.1
26 6.33 64.3
27 6.35 64.5
28 6.37 64.7
29 6.39 64.9
30 6.41 65.2
31 6.43 65.4
32 6.45 65.6
33 6.48 65.8
34 6.50 66.0
35 6.52 66.2
36 6.54 66.4
37 6.56 66.7
38 6.58 66.9
39 6.60 67.1
40 6.62 67.3
41 6.64 67.5
42 6.67 67.7
43 6.69 67.9
44 6.71 68.2
45 6.73 68.4
HD465-8, HD605-8 30-127

6. When the gauge of the gas charging tool indicates that the pressure
exceeds the specified gas pressure shown in Table 1 or Table 2.
1) Turn the handle (a) counterclockwise to close the valve
of the regulator D.
2) Turn the handle (b) counterclockwise slowly to discharge
the nitrogen gas gradually from the thread part of the
handle (b) until the gauge of the gas charging tool A indi-
cates that the pressure is the specified gas pressure shown
in the Table 1 or Table 2, and close the valve by turning the
handle (b) clockwise to adjust the nitrogen gas in the accu-
mulator (1).
7. When the accumulator is charged with the nitrogen gas to the
specified gas pressure as the Table 1 or Table 2 shows, remove
the tools according to the following procedure.
1) Turn the handle (a) and (c) counterclockwise to close the
valve of the accumulator. And the regulator D
2) Close the valve (d) of nitrogen gas cylinder F
3) Turn the handle (b) counterclockwise to open the valve,
discharge the nitrogen gas remaining in the gas charging
tool A and the hose B from the thread part of the handle (b).
4) Remove the hose B, regulator D, bushing C, and nipple E.
5) Remove the gas charging tool A from the extension A1.
6) Remove the extension A1 from the gas valve (4) of the
accumulator (1).

3 Plug (2):
73.5 to 98.0 Nm {7.5 to 10.0 kgm}
10. In 1 week after you pressurized the accumulator with nitrogen
gas, perform a brake test and make sure the nitrogen gas pres-
sure is at the proper pressure.
30-128 HD465-8, HD605-8

Make sure brake operation is measured

After 5 minutes or longer of engine stop, the oil pressure of the brake circuit is lowered and the correct test cannot be performed.
Perform the brake operation test within 5 minutes after the engine stops.
1. Put the machine on a level ground, and set the parking brake switch to OFF position.
2. Start the engine, run it at medium speed for a minute, and stop the engine.
3. Turn the start switch to ON position. Depress the brake pedal
several times, and count the number of times the brake is
depressed until the brake oil pressure caution lamp illuminates.
q When the brake is depressed less than 5 times: The accumu-
lator nitrogen gas pressure may be low
q When the brake is depressed more than 5 times: The accu-
mulator nitrogen gas pressure is normal
HD465-8, HD605-8 30-129

METHOD FOR DISCHARGING THE NITROGEN GAS WHEN DISPOSING OF THE ACCU-
MULATOR
REMARK
The discharging of the nitrogen gas is necessary when accumulator body is disposed of.
1. Connect the gas charging tool A1 to the extension A1 by referring
to steps 1 to 3 of “TEST NITROGEN GAS PRESSURE IN
BRAKE ACCUMULATOR”.
2. Turn the handle (a) clockwise slowly, and stop turning it in a light
response.
NOTICE
Do not turn handle (a) excessively, otherwise it damages the
accumulator valve core and gas may leak. Operate handle
(a) carefully.
3. Turn the handle (b) counterclockwise slowly. When the nitrogen
gas starts discharged from the thread part of the handle (b), let it
as it is, and discharge it gradually into atmosphere.
4. When the nitrogen gas is no longer discharged, left the handle (a) as it is, and remove the gas charging tool A from the
accumulator (1).
5. Remove the extension A1.
6. Dispose of the accumulator.
NOTICE
Dispose of the accumulator while the accumulator (1) gas valve (4) is left open according to step4.
30-130 HD465-8, HD605-8

30 TEST AND ADJUST TEST BRAKE PERFORMANCE
TEST BRAKE PERFORMANCE

k If the machine moves during the brake test, it may cause serious personal injury or death. If the machine moves
during the brake test, immediately lower the engine speed, shift the gear shift lever to "N" position, and depress
the brake pedal.
To perform the test to troubleshoot brake performance, refer to this section.
TEST FOOT BRAKE PERFORMANCE
3. Make sure that front brake off switch is set to OFF.

5. Shift the gear shift lever to D position with the brake pedal
correctly depressed with your left foot.
k Do not test the performance of the foot brake with the gear
shift lever in other than D position.
k If the start-off gear speed is selected other than "F2", the ma-
chine may move while depressing the brake. Make sure that
"F2" (start-off gear speed) is selected in "F1 Start at D Posi-
tion Setting" in the user menu.
REMARK
q Shift the gear shift lever to D position to make sure that "F2"
is shown on the shift indicator.
q If the gear shift lever is in D position, the centralized warning
lamp illuminates and alarm buzzer operates intermittently.
6. Depress the accelerator pedal gradually and make sure that the machine does not move when the torque converter stall is
performed at the specified engine speed.
7. Lift your right foot off the accelerator pedal, and return the gear shift lever to N position after test.
HD465-8, HD605-8 30-131

TEST BRAKE PERFORMANCE 30 TEST AND ADJUST
PROCEDURE TO TEST RETARDER BRAKE PERFORMANCE

4. Set the gear shift lever to D position with the retarder control lever
fully pulled toward the operator.
k Do not test the performance of the retarder brake with the
gear shift lever in other than D position.
chine may move while operating the retarder brake. Make
sure that "F2" (start-off gear speed) is selected in "F1 Start at
D Position Setting" in the user menu.
REMARK
q The retarder indicator lamp is illuminated when the retarder
brake is in operation.
30-132 HD465-8, HD605-8

30 TEST AND ADJUST TEST BRAKE PERFORMANCE
PROCEDURE TO TEST PARKING BRAKE PERFORMANCE

REMARK
in (P) position.
4. Shift the gear shift lever to D position.
k Do not test the performance of the parking brake with the
gear shift lever in other than D position.
chine may move while operating the parking brake. Make
sure that "F2" (start-off gear speed) is selected in "F1 Start at
D Position Setting" in the user menu.
REMARK
If the machine moves at the specified engine speed, see "TEST THE QUANTITY OF REAR BRAKE DISC WEAR" and perform
tests of brake pad.
HD465-8, HD605-8 30-133

BLEED AIR FROM BRAKE CIRCUIT 30 TEST AND ADJUST
BLEED AIR FROM BRAKE CIRCUIT

Tools to bleed air from the brake circuit

A Commercially available Hose 1 Inside diameter: About 8 mm
B Commercially available Oil container 1
When the brake circuit equipment are removed or installed, or the oil for transmission circuit or brake circuit is replaced, bleed
air from the brake circuit as follows.
To perform the air bleed from brake circuit to troubleshoot, refer to this section.
PROCEDURE TO BLEED AIR FROM FRONT BRAKE CIRCUIT
2. Measure the quantity of oil in the transmission case at the low idle condition.
REMARK
If the amount of oil is below the specified level, add oil.
REMARK
erate and air bleed procedure will not be performed.
4. Remove the cap from the air bleeder (1).
30-134 HD465-8, HD605-8

30 TEST AND ADJUST BLEED AIR FROM BRAKE CIRCUIT
5. Connect the hose A to the air bleeder (1) and put one end of hose
A into the oil container.
6. Depress the brake pedal to travel end and hold it.
7. Loosen the air bleeder (1) 3/4 turn and drain oil and air mixed.
8. If the oil and air are not mixed in drained oil, tighten the air
bleeder (1).
9. Relieve the brake pedal slowly.
10. Measure the quantity of oil in the transmission case at the low
idle condition.
REMARK
In the same way, perform the air bleeding of the front brake circuit on the opposite side.
PROCEDURE TO BLEED AIR FROM FRONT BRAKE CIRCUIT (FOR MACHINE WITH
ABS)
REMARK
REMARK
erate and air bleed procedure will not be performed.
4. Set the "ABS Setting" to ON in the operator mode.
REMARK
For details about ABS settings , see Operation and Maintenance Manual, "Method for setting ABS ".
5. Remove the cap from the air bleeders (4) and (5).
6. Connect the hose A to the air bleeders (4) and (5) and put one
end of hose A into the oil container.
8. Loosen the air bleeders (4) and (5) 3/4 turn and drain oil and air
mixed.
bleeders (4) and (5).
HD465-8, HD605-8 30-135

11. Remove the cap from the air bleeder (1).
12. Connect the hose A to the air bleeder (1) and put one end of hose
A into the oil container.
bleeder (1).
17. Set the "ABS Setting" to OFF in the operator mode.
REMARK
20. If the oil and air are not mixed in drained oil, tighten the air bleeder (1).
REMARK
REMARK
In the same way, perform the air bleeding of the front brake circuit on the opposite side.
PROCEDURE TO BLEED AIR FROM REAR BRAKE CIRCUIT
The air bleed procedure for the rear brake circuit starts at the slack adjuster and then moves to the wheel brake parts.
REMARK
30-136 HD465-8, HD605-8

3. Perform the air bleed procedure on the slack adjuster (1).

1) Remove the cap from either one of air bleeder (2).
2) Connect the air bleeding hose A to air bleeder (2) and put
one end of hose A into the oil container B.
3) Depress the brake pedal to travel end and hold it.
4) Loosen the air bleeder (2) 3/4 turn and drain oil and air
mixed.
5) If the oil and air are not mixed in drained oil, tighten the
air bleeder (2).
6) Relieve the brake pedal slowly.
7) Pull the retarder control lever to the full extent and hold it.
mixed.
9) If the oil and air are not mixed in drained oil, tighten the air bleeder (2).
10) Put the retarder control lever back to the initial position.
4. Perform the air bleed procedure on the rear wheel part.
1) Remove the cap from the air bleeder (3).
mixed.
air bleeder (3).
8) Loosen the air bleeder (3) 3/4 turn and drain oil and air mixed.
REMARK
In the same way, perform the air bleeding of the rear brake circuit on the opposite side.
HD465-8, HD605-8 30-137

PROCEDURE TO BLEED AIR FROM REAR BRAKE CIRCUIT (FOR MACHINE WITH
ABS/WITHOUT KTCS)
REMARK
REMARK
mixed.
air bleeder (2).
mixed.
11) Set the "ABS Setting" to OFF in the operator mode.
REMARK
30-138 HD465-8, HD605-8


mixed.
air bleeder (3).
mixed.
REMARK
REMARK
REMARK
HD465-8, HD605-8 30-139

KTCS)
REMARK
mixed.
air bleeder (2).
mixed.
11) Fix the KTCS valve. For details, see "SET AND
OPERATE OF MACHINE MONITOR", "PROCEDURE
TO ADJUST WITH ADJUSTMENT MENU (KTCS
VALVE SETTING)".
REMARK
q When the KTCS valve is set, "1" is shown in (a), and
KTCS will be in this condition of operation.
q The operation condition of KTCS is held until the dis-
play goes to normal.
mixed.
30-140 HD465-8, HD605-8

14) Push RETURN switch (12) several times to return to the

standard screen.
REMARK
When the standard screen is shown, KTCS operation is can-
celed.

mixed.
air bleeder (3).
VALVE SETTING)".
REMARK
mixed.
standard screen.
REMARK
When the standard screen is shown, KTCS operation is
canceled.
idle condition.
REMARK
HD465-8, HD605-8 30-141

ABS/KTCS)
The air bleed procedure for the rear brake circuit must be performed at the inside of the ABS circuit, slack adjuster and then
moves to the wheel brake part.
REMARK
REMARK
air bleeder (2).
mixed.
REMARK
20) Set the "ABS Setting" to ON in the operator mode.
REMARK
30-142 HD465-8, HD605-8

VALVE SETTING)".
REMARK
mixed.
standard screen.
REMARK
When the standard screen is shown, KTCS operation is
canceled.

mixed.
air bleeder (3).
VALVE SETTING)".
REMARK
mixed.
HD465-8, HD605-8 30-143


standard screen.
REMARK
When the standard screen is shown, KTCS operation is can-
celed.
idle condition.
REMARK
PROCEDURE TO BLEED AIR FROM PARKING BRAKE CIRCUIT
The air bleed procedure for the parking brake circuit must be performed at the differential block part and then moves to the
wheel brake part.
OFF position.
REMARK
If the machine lockout operation switch is set to ON position, the parking brake will not release and air bleed procedure
REMARK
4. Perform the air bleed procedure on the differential block part (1).
4) Set the parking brake switch to TRAVEL position.
mixed.
air bleeder (2).
8) Set the parking brake switch to (P) position.
30-144 HD465-8, HD605-8


4) Set the parking brake switch to TRAVEL position.
mixed.
air bleeder (3).
8) Set the parking brake switch to (P) position.
REMARK
HD465-8, HD605-8 30-145

TEST PARKING BRAKE OIL PRESSURE 30 TEST AND ADJUST
TEST PARKING BRAKE OIL PRESSURE

Tools to test parking brake oil pressure

A
2 799-101-5160 Fitting 1
3 790-301-1530 Elbow 1
To perform the test to troubleshoot parking brake, refer to this section.
PROCEDURE TO TEST PARKING BRAKE OIL PRESSURE
1. Set the parking brake switch to (P) position.

REMARK
gauge A1.
6. Bleed air from the parking brake circuit. For details, see TEST
AND ADJUST, "BLEED AIR FROM BRAKE CIRCUIT".
REMARK
test kit C.
7. Stop the engine and turn the start switch to the ON position.
8. Measure the oil pressure (release pressure) when the parking
brake switch is set to the TRAVEL position.
chine.
k See "BLEED AIR FROM BRAKE CIRCUIT", and make sure to
bleed air from the brake circuit.
30-146 HD465-8, HD605-8

30 TEST AND ADJUST RELEASE PARKING BRAKE MANUALLY
RELEASE PARKING BRAKE MANUALLY

Tools to release parking brake manually

A Commercially available Oil container 1
q Size: M12 × 1.75
B 01017-51245 Bolt 20 q Length under neck: 65 to 80
mm
C 01580-1210 Washer 20 Size: M12
D 01643-1232 Nut 20 Size: M12
k If a malfunction occurs in the hydraulic system, make sure to slowly pull it after the parking brake is released man-
ually as the wheel brake may not be operated normally.
k Make sure the are is safe on the level ground before you perform the manual release operation of the parking
brake. If the parking brake is released on a slope, make sure to block the tire.
k Perform it while the engine stops.
If the parking brake will not release because of a malfunction of electric system or hydraulic system of parking brake, the brake
can be manually released temporarily.
PROCEDURE TO RELEASE THE PARKING BRAKE MANUALLY
1. Stop the engine.
2. Block the tires.
3. Install the oil container A below the wheel brake.
REMARK
There are 10 plugs (1) for each on the both sides.
5. Install the 10 sets of bolt B, washer C, and nut D.
6. Tighten the nut D evenly and pull in piston (2).
7. Pull the machine at a slow speed to move it to a safety area.
k After you move the machine, make sure to block the tire.
After you move the machine, install the plug (1).
3 Plug (1):
44.1 to 53.9 Nm {4.5 to 5.5 kgm}
HD465-8, HD605-8 30-147

TEST THE AMOUNT OF FRONT BRAKE PAD WEAR 30 TEST AND ADJUST
TEST THE AMOUNT OF FRONT BRAKE PAD WEAR

Tools to test front brake pad wear

A 566-98-41410 Gauge 1 Vehicle-mounted tool
To perform the test to troubleshoot amount of front brake pad wear, refer to this section.
PROCEDURE TO VISUALLY TEST THE AMOUNT OF FRONT BRAKE PAD WEAR
1. Examine the critical brake material line (a) to judge the friction
material quantity.
q When the critical brake material line (a) is seen:
Replacement of brake pad (1) is not required.
q When the critical brake material line (a) is not seen:
Replacement of brake pad (1) is required.
NOTICE
Replace the brake pads (1) on the both sides at the same
time.
REMARK
The figure shows an example of the brake pad on the left front of the opposite side.
2. Inspect the front brake pad on the opposite side.
REMARK
The friction material quantity is different between left and right, test all of the brake pads.
PROCEDURE TO TEST FRONT BRAKE PAD WEAR WITH GAUGE MEASURE
1. Depress the brake pedal to travel end.
REMARK
The brake pad is pushed on the disc.
2. Remove the cap from the inspection port (d).
3. Engage the gauge A until it touches the inspection port (d) and
measure the brake material quantity.
q When there is distance (e) between step part (c) and caliper
(3):
Replacement of brake pad (1) is not required.
REMARK
(e) is the thickness of the brake pad before the wear limit.
For standard values, see STANDARD VALUE TABLE,
"STANDARD VALUE TABLE FOR MACHINE".
q When step part (c) of gauge A touches the caliper:

Replacement of brake pad (1) is required.
NOTICE
Replace the brake pads (1) on the both sides at the same
time.
chine.
30-148 HD465-8, HD605-8

30 TEST AND ADJUST TEST THE QUANTITY OF REAR BRAKE DISC WEAR
TEST THE QUANTITY OF REAR BRAKE DISC WEAR

To perform the test to troubleshoot amount of rear brake pad wear, refer to this section.
PROCEDURE TO TEST THE QUANTITY OF REAR BRAKE DISC WEAR
Perform this check while the engine is stopped.
1. Make sure that the brakes other than the parking brake are not in operate.
2. Remove the cap nut (1) of gauge.
3. Engage the gauge (2) until it touches the piston (3) and measure
the brake material quantity.
q When wear limit (b) of part D touches the edge face of guide
(4):
Replacement of disc is required.
q When wear limit (b) of part D does not touch the edge face of
guide (4):
Replacement of disc is not required.
NOTICE
q When the wear limit touches the vicinity of wear limit,
shorten the interval of inspection even if replacement of
disc is not required.
q Do not loosen the attached nut (5) of guide (4) to avoid
that the adjustment position is aligned.
REMARK
q The figure shows an example of the rear brake part on the
right side.
q When a vehicle is new, step part (a) of gauge (2) is adjusted
to be aligned with the edge of guide (4).
Inspect the front brake pad on the opposite side.
REMARK
The friction material quantity is different between left and right,
test all of the brake pads.
After you finish the test, assemble the machine.
3 Cap nut:
128 to 186 Nm {13 to 19 kgm}
HD465-8, HD605-8 30-149

TEST AND ADJUST HOIST CIRCUIT OIL PRESSURE 30 TEST AND ADJUST
HYDRAULIC SYSTEM
TEST AND ADJUST HOIST CIRCUIT OIL PRESSURE
Tools to test hoist circuit oil pressure

A
D 07002-11023 O-ring 1
To perform the test to troubleshoot hoist circuit oil pressure, refer to this section.
PROCEDURE TO TEST HOIST CIRCUIT OIL PRESSURE
REMARK
The plug (2) for the machine with machine lock-out is on the right
side of the machine.
30-150 HD465-8, HD605-8

30 TEST AND ADJUST TEST AND ADJUST HOIST CIRCUIT OIL PRESSURE
REMARK
gauge A1.
7. Pull out the body pivot pin.
NOTICE
Replace the body pivot pin to the initial position.
sure that the machine lock-out operation switch is set to OFF position.
REMARK
If the machine lockout operation switch is set to ON position, oil does not flow to the hoist circuit and oil pressure test cannot
be performed.
11. Lift the dump body until the hoist cylinder comes to travel end.
12. Depress the accelerator pedal to travel end. (high idle).
13. Operate the dump lever and lift the dump body to measure the
pressure when it is relieved.
chine.
PROCEDURE TO ADJUST HOIST CIRCUIT OIL

PRESSURE
If the hoist circuit relief pressure is not normal, adjust the relief valve
(1) on the hoist valve.

2. Turn the adjustment screw (3) to adjust oil pressure.
q Turn the adjustment screw (3) to the right to raise the pres-
sure.
q Turn the adjustment screw (3) to the left to lower the pres-
sure.
q Pressure adjustment for 1 turn of adjustment screw (3): 4.2
MPa {42.8 kg/cm2}
3. Tighten the locknut (3).
3 Locknut (3):
29.4 to 39.2 Nm {3 to 4 kgm}
After you finish the adjustment, measure the hoist circuit oil pressure again.
HD465-8, HD605-8 30-151

TEST HOIST CYLINDER SUPPLY PRESSURE 30 TEST AND ADJUST
TEST HOIST CYLINDER SUPPLY PRESSURE

Tools to test hoist cylinder pressure

A
D 07002-11023 O-ring 1
To perform the test to troubleshoot hoist cylinder supply pressure, refer to this section.
PROCEDURE TO TEST HOIST CYLINDER SUPPLY PRESSURE
REMARK
gauge A1.
NOTICE
position.
REMARK
If the machine lockout operation switch is set to ON position, oil
does not flow to the hoist circuit and oil pressure test cannot be
performed.
30-152 HD465-8, HD605-8

30 TEST AND ADJUST TEST HOIST CYLINDER SUPPLY PRESSURE
11. Lift the dump body until the hoist cylinder comes to travel end.
13. Operate the dump lever and lift the dump body to measure the
pressure when it is relieved.
chine.
HD465-8, HD605-8 30-153

TEST OIL PRESSURE OF HOIST EPC VALVE CIRCUIT 30 TEST AND ADJUST
TEST OIL PRESSURE OF HOIST EPC VALVE CIRCUIT

Tools to test hoist EPC valve circuit oil pressure

A
C 790-301-1210 Joint 1 Size: M14 x 1.5 - Rc1/8
E 07002-11023 O-ring 2
F 799-401-3100 Adapter 1 Size: 02
To perform the test to troubleshoot hoist EPC valve circuit oil pressure, refer to this section.
PROCEDURE TO TEST HOIST EPC VALVE SUPPLY PRESSURE
5. Remove the plug (1) of the hoist EPC valve.
q For automatic suspension and machine lock-out specifica-
tion:
Disconnect the hose and connect the adapter F.
6. Install the joint C and fitting D.

q For automatic suspension specification:
Install the fitting D.
REMARK
gauge A1.
NOTICE
OFF position.
12. Measure the oil pressure when the accelerator pedal is fully depressed.
30-154 HD465-8, HD605-8

30 TEST AND ADJUST TEST OIL PRESSURE OF HOIST EPC VALVE CIRCUIT
PROCEDURE TO TEST HOIST EPC VALVE OUTLET PRESSURE

2. Disconnect the hose (1) or (2) on the hoist valve inlet side.
q To measure the outlet pressure with the dump lever at the
"Up" position:
Disconnect the hose (1). (PB port side of hoist valve)
q To measure the outlet pressure with the dump lever at the
"Down" position:
Disconnect the hose (2). (PA port side of hoist valve)
3. Install the adapter F and connect the hose (1) or (2).

REMARK
gauge A1.
position.
8. Depress the accelerator pedal to travel end. (high idle)
9. Measure the oil pressure when the dump lever is at as follows.
q "Up" position
q "Float" position
q "Down" position
chine.
HD465-8, HD605-8 30-155

TEST RADIATOR FAN CIRCUIT OIL PRESSURE 30 TEST AND ADJUST
TEST RADIATOR FAN CIRCUIT OIL PRESSURE

Tools to test radiator fan circuit oil pressure

A
C 799-401-3500 Adapter 1 Size: 06
k Loosen the hydraulic tank oil filler cap slowly to release the pressure in the tank.
q Fan mode fixed: Max.
To perform the test to troubleshoot radiator fan circuit oil pressure, refer to this section.
PROCEDURE TO TEST RADIATOR FAN CIRCUIT OIL PRESSURE

1. Remove the underguard (1).
2. Disconnect the hose (1).
30-156 HD465-8, HD605-8

30 TEST AND ADJUST TEST RADIATOR FAN CIRCUIT OIL PRESSURE
3. Install the adapter C, and connect the hose (1) again.

tester A.
REMARK
gauge A1.

screen. Set the fan mode to "2: Max". For details, see "SET AND
OPERATE OF MACHINE MONITOR", "PROCEDURE TO
ADJUST (FAN MODE FIXING)".
9. Measure the oil pressure when the accelerator pedal is fully
depressed (high idle).
chine.
HD465-8, HD605-8 30-157

TEST AND ADJUST FRONT SUSPENSION CYLINDER 30 TEST AND ADJUST
TEST AND ADJUST FRONT SUSPENSION CYLINDER

Tools to test and adjust front suspension cylinder

1 792-610-1130 Pump 1
B
2 792-610-1110 Hose 1
3 792-610-2200 Joint 1
1 07020-21732 Fitting 1
2 792-610-1140 Joint 1
C
4 792-610-1260 Fitting 1
5 792-610-1270 Hose 1
6 792-610-1280 Valve 1
7 792-610-1400 Regulator 1

F Commercially available Nitrogen gas cylinder 1
G Commercially available Oil pressure jack 1 Lift: Min. 50 t
k When you fill cylinders with nitrogen gas, put on the appropriate protection equipment (goggles, leather gloves,
protective clothes) to prevent nitrogen gas leaks on your skin or clothes. Perform the work on the up wind side as
much as possible.
Measure and adjust this item in these conditions.
q On a horizontal road
q Engine: Stopped
q Dump body: Empty
To perform the test to troubleshoot front suspension cylinder, refer to this section.
PROCEDURE TO TEST FRONT SUSPENSION CYLINDER
1. Measure the installed length of cylinder.
1) Make sure that the lower end of the cylinder cover is in
the range of arrows (a) of the cylinder length level.
30-158 HD465-8, HD605-8

30 TEST AND ADJUST TEST AND ADJUST FRONT SUSPENSION CYLINDER
PROCEDURE TO ADJUST FRONT SUSPENSION CYLINDER

Procedure to release nitrogen gas
1. Set the oil pressure jack G below the lower part of the frame.
k Make sure to set the oil pressure jack G firmly to prevent
it come off from the frame.
2. Remove the cover from the suspension cylinder.
3. Disconnect the pressure sensor connector (2) of oil level valve
(1).
REMARK
Step 3 is for only when the pressure sensor is installed. If the
pressure sensor is not installed, go to step 4.
4. Slowly loosen oil level valve (1) 2 to 3 turns and hold that position
when nitrogen gas starts to be released.
NOTICE
Releasing nitrogen gas from the feed valve (3) may damage
the valve core. Release nitrogen gas only by oil level valve
(1).
REMARK
q If nitrogen gas and oil release together from oil level valve (1),
tighten the oil level valve (1) to lower the release of nitrogen
gas until oil does not come out.
q When you loosen the oil level valve (1), loosen the valve body
only and do not loosen the pressure sensor and fitting.
5. Operate the oil pressure jack G to slowly lower the frame until the dimension of suspension cylinder (b) becomes the length
of the specified capacity.
NOTICE
Operate the oil pressure jack G carefully to avoid damage to the suspension cylinder.
Fill length of specified capacity (b): 85±3 mm
When the cylinder installed length is incorrect, adjust the length.
HD465-8, HD605-8 30-159

Procedure to adjust oil level

Adjust the oil level after you finish release the nitrogen gas.
1. Remove the valve body of feed valve (3) and install the joint C2.
2. Install the fitting C1 to the joint B3 and connect the hose B2 and
pump B1.
3. Loosen the air bleed valve (4) first, operate the pump B1, and
remove the nitrogen gas from the side air bleed hole (c).
REMARK
Fill oil until oil without air bubbles flows out.
4. When oil without air bubbles flows out, tighten the air bleed valve
(4).
3 Air bleed valve (4)
39.2 to 49.0 Nm {4 to 5 kgm}
5. Remove the oil level valve (1) and operate the pump B1.
REMARK
6. When oil without air bubbles flows out, tighten the oil level valve
(1).
3 Oil level valve (1):
39.2 to 49.0 Nm {4 to 5 kgm}
7. Remove each adjust tool described in step 1 and 2, and install
the feed valve (3).
3 Feed valve (3):
39.2 to 49.0 Nm {4 to 5 kgm}
30-160 HD465-8, HD605-8

30 TEST AND ADJUST TEST AND ADJUST FRONT SUSPENSION CYLINDER
Procedure to pressurize nitrogen gas

Pressurize with nitrogen after you complete the oil level adjustment.
1. Remove the cap from the feed valve (3).
2. Connect the adjust tool C3 to C7 and gauge D and E as shown
in the figure.
REMARK
q Connect the valve C6 to feed valve (3).
q Prevent unwanted material entry by blowing nitrogen gas to
the filter of the metal cap of regulator C7 before installation.
3. Open the valve (5) of nitrogen gas cylinder F and examine the
indicated pressure (inside pressure of the cylinder) of gauge D.
REMARK
Set the indicated pressure minimum 1 MPa {10 kg/cm2} higher
than the cylinder internal pressure.
Cylinder internal pressure (reference)
Front left, right: 4.31 MPa {44.0 kg/cm2}
4. Turn the handle of regulator C7 left gradually and set the indi-
cated pressure of gauge E.
NOTICE
Do not expand the cylinder to travel end with pressurized ni-
trogen gas into the cylinder.
5. Pressurize the suspension cylinder with nitrogen gas by operation of the handles on valve C3 and C6.
REMARK
Pressurize nitrogen gas into the left and right cylinders at the same time.
6. When the length of the left and right cylinders gets the specified
installed length, turn the handle of regulator C7 right to stop the
fill procedure of nitrogen gas.
Front installed length (c): 255±10 mm
7. Fully turn the handle of valve C6 back and loosen air bleed plug
(6) of the valve C3 to release gas in the hose.
8. Remove adjust tool C3 to C7 and gauge D and E described in
step 2.
NOTICE
Be careful not to lose O-ring of feed valve.
9. Install the cover of suspension cylinder.
HD465-8, HD605-8 30-161

Procedure to adjust cylinder installed length

q Adjust the cylinder installed length you complete the fill procedure with nitrogen gas.
q Adjust the cylinder installed length with the dump body with empty load and on the flat ground.
1. Move the machine forward for approximately 15 m and stop. Then move it rearward and make a sudden stop in the initial
position.
2. Repeat step 1 to 3 or 4 times. To stop the machine at last, operate the retarder brake little by little to slowly stop the
machine.
REMARK
Stop the machine as slow as possible with the retarder brake to project of seals and bushing of the cylinder.
3. Measure the cylinder installed length.
4. If the installed length is long, release nitrogen gas from the oil
level valve to adjust length.
NOTICE
Release nitrogen gas by pushing the tip of valve core (7)
may damage valve core (7). Do not perform this.
REMARK
q To release nitrogen gas, loosen the oil level valve a small
quantity to prevent cylinder movement.
q When you release the nitrogen gas and the cylinder moves, the length may become shorter than the specified installed
length. Be careful of this case.
5. After you finish the adjustment, measure the cylinder length as in step 1 to 3.
6. Examine for gas leakage of valve core (7), oil level valve (1), and
the cylinder ground.
REMARK
q Perform the gas leakage test using soap and water.
q If gas leaks from valve core (7), replace the valve core.
2 Valve core (7):
Liquid adhesive (LT-1A)
3 Valve core (7):
29±5 Nm {2.96±0.51 kgm}
q Note 1. Test after oil change and filled with gas
If the machine is operated after oil change or gas change, gas volume decreases and the cylinder length lowers below
the standard value because gas is mixed with oil in the cylinder.
For this reason, measure the installation length of the cylinder 48 hours after the oil and gas change. Gas adjustment
needs to be done if the length is less than regulation length.
q Note 2. Test for cylinder length because of temperature change
The cylinder length of the suspension changes because gas expands or retracts corresponding to the temperature dur-
ing operation.
For this reason, adjust the cylinder installed length to the specified range by daily inspection in the regions where tem-
perature difference is large throughout a year.
30-162 HD465-8, HD605-8

TEST AND ADJUST FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPEN-
30 TEST AND ADJUST SION SPECIFICATION)
TEST AND ADJUST FRONT SUSPENSION CYLINDER (AUTO-

MATIC SUSPENSION SPECIFICATION)
q Engine: Stopped
q Dump body: Empty
q Soft mode
q Parking brake: P position
q Dump lever: Float
To perform the test to troubleshoot suspension cylinder, refer to this section.
PROCEDURE TO TEST FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION
SPECIFICATION)
1. With the check condition described in this section, make sure the
cylinder of the variable damping valve is in S position (soft
mode).
S position: Soft mode
H position: Hard mode
M position: Medium mode
REMARK
If the cylinder is not in S position (soft mode), move the machine
forward and back several times using the retarder brake to set
the cylinder to S position (soft mode).
2. Turn the start switch to ON position.
3. Measure the length (a) of suspension cylinder (1).
Regulation length (a): 352±1 mm
4. Change the hoist lever to a position other than the float position.
5. Make sure that the installed length (a) of suspension cylinder (1)
is longer than the regulation length.
REMARK
q For hard mode (b): 383±1 mm (refer)
q For medium mode (d): 414±1 mm (refer)
HD465-8, HD605-8 30-163

TEST AND ADJUST FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPEN-
SION SPECIFICATION) 30 TEST AND ADJUST
PROCEDURE FOR ADJUSTING FRONT SUSPENSION CYLINDER (AUTOMATIC SUS-

PENSION SPECIFICATION)
1. Remove the mount bolt (2) of oil pressure cylinder (1) and
disconnect the oil pressure cylinder.
2. Loosen the locknut (3) and adjust the installed regulation length
by rod end (4).
Regulation length (a): 352±1 mm
3. Install the oil pressure cylinder and tighten mount bolt (2).
4. See "PROCEDURE FOR ADJUSTING FRONT SUSPENSION
CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION)" to
check installed length of the suspension cylinder (a) when the
hoist lever is set to a position other than the float position.
5. Make sure the hole of bracket (5) is in slit part (e) of lever (6)
when in soft mode and medium mode.
30-164 HD465-8, HD605-8

30 TEST AND ADJUST TEST AND ADJUST REAR SUSPENSION CYLINDER
TEST AND ADJUST REAR SUSPENSION CYLINDER

Tools to test and adjust rear suspension cylinder

1 792-610-1130 Pump 1
B
2 792-610-1110 Hose 1
3 792-610-2200 Joint 1
1 07020-21732 Fitting 1
2 792-610-1140 Joint 1
C
4 792-610-1260 Fitting 1
5 792-610-1270 Hose 1
6 792-610-1280 Valve 1
7 792-610-1400 Regulator 1

F Commercially available Nitrogen gas cylinder 1
G Commercially available Block 1 Thickness: 19 mm
k When you fill cylinders with nitrogen gas, put on the appropriate protection equipment (goggles, leather gloves,
protective clothes) to prevent nitrogen gas leaks on your skin or clothes. Perform the work on the up wind side as
much as possible.
Measure and adjust this item in these conditions.
q Engine: Stopped
q Dump body: Empty
To perform the test to troubleshoot rear suspension cylinder, refer to this section.
PROCEDURE TO TEST REAR SUSPENSION CYLINDER
Procedure to test cylinder installed length
1. Remove the dust cover.
2. Measure the standard length (a) of the rear suspension cylinder.
Standard length (a): 204±10 mm
REMARK
Standard length (a) is also written on the label on the cylinder.
HD465-8, HD605-8 30-165

TEST AND ADJUST REAR SUSPENSION CYLINDER 30 TEST AND ADJUST
Procedure to test dust cover

1. Make sure whether the cover (1) is not damaged.
REMARK
If the cover (1) is damaged, replace it to a new one.
2. Make sure that hook (2) is installed correctly.
REMARK
If the hook (2) is off, attach it after you remove material such as
adhered mud.
3. Examine for detached or loosened band (3).
REMARK
If detached or loosened band (3) is found, tighten it.
3 Band (3):
6.8±0.49 Nm {0.69±0.05 kgm}
PROCEDURE TO ADJUST REAR SUSPENSION CYLINDER

Procedure to release nitrogen gas
1. Set the block G between the stopper and axle housing.
2. Remove the cover from the suspension cylinder.
3. Disconnect the pressure sensor connector (2) of oil level valve
(1).
REMARK
Step 3 is for only when the pressure sensor is installed. If the
pressure sensor is not installed, go to step 4.
30-166 HD465-8, HD605-8

4. Slowly loosen oil level valve (1) 2 to 3 turns and hold that position
when nitrogen gas starts to be released.
NOTICE
q Releasing nitrogen gas from the feed valve (3) may dam-
age the valve core. Release nitrogen gas only by oil level
valve (1).
q When you loosen the oil level valve, gradually loosen the
valve body (1) only and do not remove it until nitrogen
gas completely gone from the slit part.
q Never loosen the pressure sensor (5) until the nitrogen
gas completely released, because the pressure is on it at
all times.
REMARK
q If nitrogen gas and oil release together from oil level valve (1),
tighten the oil level valve (1) to lower the release of nitrogen
gas until oil does not come out.
q When you loosen the oil level valve (1), loosen the valve body
only and do not loosen the pressure sensor and fitting.
5. Shorten it until the length of suspension cylinder (b) goes to oil
quantity regulation length.
Oil quantity regulation length (b): 124±3 mm
Procedure to adjust oil level
Adjust the oil level after you finish release the nitrogen gas.
1. Remove the valve body of feed valve (3) and install the joint C2.
2. Install the fitting C1 to the joint B3 and connect the hose B2 and
pump B1.
3. Loosen the air bleed valve (1) first, operate the pump B1, and
remove the nitrogen gas from the air bleed valve (1).
REMARK
4. When oil without air bubbles flows out, tighten the air bleed valve
(4).
5. Remove each adjust tool described in step 1 and 2, and install
the feed valve (3).
3 Feed valve (3):
39.2 to 49.0 Nm {4 to 5 kgm}
HD465-8, HD605-8 30-167

TEST AND ADJUST REAR SUSPENSION CYLINDER 30 TEST AND ADJUST
Procedure to pressurize nitrogen gas

Pressurize with nitrogen after you complete the oil level adjustment.
1. Remove the cap from the feed valve (3).
2. Connect the adjust tool C3 to C7 and gauge D and E as shown
in the figure.
REMARK
q Connect the valve C6 to feed valve (3).
q Prevent unwanted material entry by blowing nitrogen gas to
the filter of the metal cap of regulator C7 before installation.
3. Open the valve (5) of nitrogen gas cylinder F and examine the
indicated pressure (inside pressure of the cylinder) of gauge D.
REMARK
Set the indicated pressure minimum 1 MPa {10 kg/cm2} higher
than the cylinder internal pressure.
Cylinder internal pressure (reference)
Rear: 2.74 MPa {28 kg/cm2}
4. Turn the handle of regulator C7 left gradually and set the indi-
cated pressure of gauge E.
NOTICE
Do not expand the cylinder to travel end with pressurized ni-
trogen gas into the cylinder.
5. Pressurize the suspension cylinder with nitrogen gas by operation of the handles on valve C3 and C6.
REMARK
Pressurize nitrogen gas into the left and right cylinders at the same time.
6. When the length of the left and right cylinders gets the specified
installed length, turn the handle of regulator C7 right to stop the
fill procedure of nitrogen gas.
7. Fully turn the handle of valve C6 back and loosen air bleed plug
(6) of the valve C3 to release gas in the hose.
8. Remove adjust tool C3 to C7 and gauge D and E described in
step 2.
NOTICE
Be careful not to lose O-ring of feed valve.
9. Install the cover of suspension cylinder.
30-168 HD465-8, HD605-8

Procedure to adjust cylinder installed length

q Adjust the cylinder installed length you complete the fill procedure with nitrogen gas.
q Adjust the cylinder installed length with the dump body with empty load and on the flat ground.
1. Move the machine forward for approximately 15 m and stop. Then move it rearward and make a sudden stop in the initial
position.
2. Repeat step 1 to 3 or 4 times. To stop the machine at last, operate the retarder brake little by little to slowly stop the
machine.
REMARK
Stop the machine as slow as possible with the retarder brake to project of seals and bushing of the cylinder.
3. Measure the cylinder installed length.
4. If the installed length is long, release nitrogen gas from the oil
level valve to adjust length.
NOTICE
Release nitrogen gas by pushing the tip of valve core (7)
may damage valve core (7). Do not perform this.
REMARK
q To release nitrogen gas, loosen the oil level valve a small
quantity to prevent cylinder movement.
q When you release the nitrogen gas and the cylinder moves, the length may become shorter than the specified installed
length. Be careful of this case.
5. After you finish the adjustment, measure the cylinder length as in step 1 to 3.
6. Examine for gas leakage of valve core (7), oil level valve, and the
cylinder ground.
REMARK
q Perform the gas leakage test using soap and water.
q If gas leaks from valve core (7), replace the valve core.
2 Valve core (7):
Liquid adhesive (LT-1A)
3 Valve core (7):
29±5 Nm {2.96±0.51 kgm}
q Note 1. Test after oil change and filled with gas
If the machine is operated after oil change or gas change, gas volume decreases and the cylinder length lowers below
the standard value because gas is mixed with oil in the cylinder.
For this reason, measure the installation length of the cylinder 48 hours after the oil and gas change. Gas adjustment
needs to be done if the length is less than regulation length.
q Note 2. Test for cylinder length because of temperature change
The cylinder length of the suspension changes because gas expands or retracts corresponding to the temperature dur-
ing operation.
For this reason, adjust the cylinder installed length to the specified range by daily inspection in the regions where tem-
perature difference is large throughout a year.
HD465-8, HD605-8 30-169

TEST KTCS CIRCUIT OIL PRESSURE (FOR MACHINE WITH KTCS) 30 TEST AND ADJUST
TEST KTCS CIRCUIT OIL PRESSURE (FOR MACHINE WITH KTCS)

Tools to test KTCS circuit oil pressure

A
2 799-101-5160 Fitting 1
3 790-301-1530 Elbow 1
To perform the test to troubleshoot KTCS oil pressure circuit, refer to this section.
PROCEDURE TO TEST THE OIL PRESSURE OF KTCS CIRCUIT WITH TEST TOOLS
REMARK
goes to normal.
2. Start the engine and measure the oil pressures of "KTCS Pres-
sure (Rear Left)" and "KTCS Pressure (Rear Right)".
PROCEDURE TO TEST THE OIL PRESSURE OF KTCS CIRCUIT WITH TEST TOOLS
Test the left and right oil pressure of KTCS circuit.
1. Depress the brake pedal minimum 100 times to release the pres-
sure in the brake accumulator circuit.

brake circuit.
REMARK
test kit C.
30-170 HD465-8, HD605-8

30 TEST AND ADJUST TEST KTCS CIRCUIT OIL PRESSURE (FOR MACHINE WITH KTCS)
REMARK
gauge A1.
REMARK
goes to normal.
8. Measure the oil pressure with KTCS operating.
HD465-8, HD605-8 30-171

TEST AND ADJUST DUMP BODY POSITIONER SENSOR 30 TEST AND ADJUST
WORK EQUIPMENT
TEST AND ADJUST DUMP BODY POSITIONER SENSOR
To perform the adjustment to troubleshoot body positioner sensor, refer to this section.
If the dump body positioner rod was disconnected or connected or if the body positioner sensor was removed and installed,
the body positioner sensor must be adjusted.
PROCEDURE TO TEST THE BODY POSITION SENSOR
1. Select the following monitoring items. For details, see "SET AND
Monitoring code: 34602 "Body Positioner Sensor Voltage"
3. Measure the voltage when the dump lever is set to the down
travel end and up travel end.
PROCEDURE TO ADJUST DUMP BODY POSITION SENSOR

Adjust link length
2. Remove the mount bolt (2).
3. Turn the rod end (3), and adjust the length of link (4).
Standard installed length (a) of link: 440 mm
REMARK
Do not set the installed length (a) to 436 mm or less.
Input voltage becomes:
q Lower voltage by the increase in the link length.
q Higher voltage by decrease in the link length.
4. Install the mount bolt (2).
5. Tighten the locknut (1).
6. Make sure that the input voltage is normal. For details, see
"PROCEDURE TO TEST THE BODY POSITION SENSOR".
PROCEDURE TO CALIBRATION AFTER YOU ADJUST BODY POSITION SENSOR

Do this adjustment in these conditions.
2. Select the following monitoring items. For details, see "SET AND OPERATE OF MACHINE MONITOR".
REMARK
Monitor performed on the "Pre-defined Monitoring" (01/28) screen.
30-172 HD465-8, HD605-8

30 TEST AND ADJUST TEST AND ADJUST DUMP BODY POSITIONER SENSOR
4. Seat the dump body with the accelerator pedal not depressed
(low idle), set the dump lever to "Float" position, and then hold it
for 5 seconds or longer.
REMARK
Make sure that the dump body float caution lamp is OFF.
5. Raise the dump body to travel end with the accelerator pedal not
depressed (low idle), set the dump lever to "RAISE" position, and
then hold it for 5 seconds or longer.
6. Seat the dump body with the accelerator pedal not depressed
(low idle).
7. Depress the accelerator pedal to travel end (high idle), and raise the dump body to travel end.
8. Release the accelerator pedal (low idle), and then set the dump lever to "Down" position. When the body starts lower, move
the lever to "Float" position to seat the dump body.
9. Repeat above steps 4 to 8, 5 to 10 times.
10. Depress the accelerator pedal to travel end (high idle), and raise the dump body to travel end.
11. Set the dump lever to "Down" position with the accelerator pedal depressed to travel end. When the body starts lowering,
return the lever to "Float" position to seat the dump body.
12. Repeat above steps 10 to 11, 5 to 10 times.
HD465-8, HD605-8 30-173

LOWER THE BODY MANUALLY 30 TEST AND ADJUST
LOWER THE BODY MANUALLY

k When the dump body is lowered manually, make sure to perform from the ground and never go under the body.
If the body cannot be lifted down due to malfunction of the controller or electric system, it can be lifted down manually according
to this section.
PROCEDURE TO LOWER THE BODY MANUALLY
3. Loosen the locknut (3) of the manual lower valve (2) on the head
side.
4. Turn the grip (4) of valve (2) counterclockwise.
5. Loosen the locknut (6) of the manual lower valve (5) on the
bottom side.
6. Turn the grip (7) of valve (5) counterclockwise to lower the dump
body.
REMARK
When the dump body starts to lower naturally, adjust the rotation
amount of the grip (7) to lower the dump body at a safe speed.
7. After the dump body stops, turn grip (7) on the bottom side clockwise to tighten the locknut (6).
8. Turn grip (4) on the head side clockwise to tighten locknut (3).
After you lower manually, assemble the machine.
30-174 HD465-8, HD605-8

30 TEST AND ADJUST LIFT THE BODY MANUALLY
LIFT THE BODY MANUALLY

Tool to manually lift the body

A 792T-491-1110 Plug 1
k When the dump body is lifted, make sure to put the dump lever back to the keep position and put the dump lever
lock knob to the locked position. Make sure to engage the body pivot pins.
If the body cannot be lifted up due to malfunction of the controller or electric system, it can be lifted up manually according to
this section.
PROCEDURE TO RAISE THE BODY MANUALLY
2. Remove the plug (1) of hoist valve.
3. Insert the plug A and tighten it.
3 Plug A:
44.1 to 53.9 Nm {4.5 to 5.5 kgm}
REMARK
When plug A is fully engaged, the spool inside the hoist valve
moves to the maximum travel on the down side.
4. Start the engine and lift up the dump body.
k Make sure to engage the body pivot pin after the body is lifted up.
q When the engine will not operate:
Set the secondary steering switch to ON to lift up the dump body.
NOTICE
q Do not operate the secondary steering function for 90 seconds or more to avoid that the secondary
steering motor is burned or damaged.
q If the load cannot be lifted down within 90 seconds, stop the secondary steering motor and wait until
its temperature goes down, and start the operation again.
5. Stop the engine.
6. Remove the plug A and install the plug (1).
3 Plug (1):
44.1 to 53.9 Nm {4.5 to 5.5 kgm}
HD465-8, HD605-8 30-175

ADJUST STEERING WHEEL TILT LOCK LEVER 30 TEST AND ADJUST
CAB AND ITS ATTACHMENTS

ADJUST STEERING WHEEL TILT LOCK LEVER
If the positions of tilt and telescopic are not aligned even if the steering tilt lock lever is set to the locked position, you can adjust
it according to this section.
PROCEDURE TO ADJUST STEERING WHEEL TILT LOCK LEVER
1. Put the lock lever (1) to the free position and put the tilt quantity
to the minimum level.
2. Put the lock lever (1) to the locked position.
3. Move the connector cap (2) up.
REMARK
When the optional switch is attached, do not force or pull the har-
ness.
4. Remove the bolt (3) and washer (4) which set the lock lever (1).
5. Remove the lock lever (1) to the left.
6. Put the lock lever (1) from the initial position (a) to the upper posi-
tion (b).
REMARK
Move up the position of lock lever (1) raise the tighten force at the
lock position.
7. Install the washer (4) and tighten the bolt (3).
3 Bolt (3):
16 to 20 Nm {1.63 to 2.04 kgm}
8. Back the connector cap (2) to the initial position.
30-176 HD465-8, HD605-8

30 TEST AND ADJUST ADJUST STEERING WHEEL TILT LOCK LEVER
9. Make sure the looseness of lock lever (1) and tilt and telescopic adjustment.
q Looseness of lock lever (1):
Operate and make sure that the lock position of lock lever (1) is tight.
q Tilt adjustment, telescopic adjustment:
Make sure that lock lever (1) can adjust the position of steering wheel at the free position.
HD465-8, HD605-8 30-177

ADJUST RATTLING OPERATOR'S SEAT 30 TEST AND ADJUST
ADJUST RATTLING OPERATOR'S SEAT

To perform the adjustment when the operator's seat or cushion seat has play, refer to this section.
METHOD FOR ADJUSTING RATTLING OPERATOR'S SEAT
1. Slide the operator's seat or seat cushion so that they can be
adjusted with the adjustment screw.
REMARK
q Adjustment screw (1) for the whole operator's seat is on the
left side.
q Adjustment screw (2) for the seat cushion is on the right side.
2. Turn the adjustment screw (1) or (2) with a hexagonal wrench.

q If the adjustment screw (1) or (2) is turned clockwise:
Loose seat is less movable and the operating effort to slide
the seat or seat cushion is increased.
q If the adjustment screw (1) or (2) is turned counterclockwise:
Loose seat moves more and the operating effort to slide the
seat or seat cushion is decreased.
REMARK
The adjustment screws are already coated with loctite. Screws
do not need to be coated again.
After adjustment, slide the operator's seat or seat cushion and test if the operator's seat rattles.
30-178 HD465-8, HD605-8

30 TEST AND ADJUST SET AND ADJUST EACH EQUIPMENT
ELECTRICAL SYSTEM
SET AND ADJUST EACH EQUIPMENT
Use the machine monitor to set or adjust as appropriate during replacement or disassembly. There is more installation of com-
ponents shown in the table below is performed.
Contents of operation Required setting/adjustment Reference

See Operation and Maintenance Manual,
Language setting
"Language Setting".
PROCEDURE TO SET WITH DEFAULT
Machine model selection setting SETTING MENU (MACHINE MODEL
SELECT)
Option selection setting
SETTING MENU (OPTION SELECTION)
PROCEDURE FOR SETTING WITH
Unit setting
DEFAULT SETTING MENU (UNIT)
Clearing electrical system abnormality PROCEDURE TO CERTIFY ABNORMALITY
record RECORD (ELECTRICAL SYSTEMS)
Replacement of the monitor Service meter setting -

controller
Odometer setting -
Reverse travel odometer setting -
KOMTRAX terminal setting -
PROCEDURE TO SET AUTO-IDLE STOP
Auto idle stop setting TIMER SETTING WITH THE DEFAULT
SETTING MENU
PROCEDURE FOR OPERATING PHONE
Phone number entry (*1)
NUMBER ENTRY SETTING
User password setting (*1) -
USAGE LIMITATION AND CHANGE
Usage limitation password setting (*1)
MAINTENANCE PASSWORD
SELECT)
SETTING MENU (OPTION SELECTION)
PROCEDURE TO ADJUST ECMV
Transmission ECMV current adjustment AUTOMATIC COMPENSATION WITH
Replacement of the ADJUSTMENT MENU
Resetting initial learning of transmission and PROCEDURE TO ADJUST T/M INITIAL
implementation of learning LEARNING WITH ADJUSTMENT MENU
Clearing electrical system abnormality PROCEDURE TO CERTIFY ABNORMALITY
record RECORD (ELECTRICAL SYSTEMS)
Maximum speed limit function setting METHOD TO SET TRAVEL SPEED LIMIT
(For machine with maximum speed limit (FOR MACHINE WITH MAXIMUM SPEED
function) LIMIT FUNCTION)
PROCEDURE TO ADJUST ECMV
Replacement or Transmission ECMV current adjustment AUTOMATIC COMPENSATION WITH
disassembly/assembly of ADJUSTMENT MENU
transmission unit or
transmission ECMV solenoid Resetting initial learning of transmission and PROCEDURE TO ADJUST T/M INITIAL
implementation of learning LEARNING WITH ADJUSTMENT MENU
HD465-8, HD605-8 30-179

SET AND ADJUST EACH EQUIPMENT 30 TEST AND ADJUST

SELECT)
Replacement of the retarder PROCEDURE TO SET WITH DEFAULT
and hoist controller SETTING MENU (OPTION SELECTION)
PROCEDURE TO CERTIFY
Clearing electrical system abnormality
ABNORMALITY RECORD (ELECTRICAL
record
SYSTEMS)
Replacement or
disassembly/assembly of the TEST AND ADJUST DUMP BODY
Body positioner sensor adjustment
body positioner sensor or POSITIONER SENSOR
body positioner rod
Replacement or
disassembly/assembly of PROCEDURE TO BLEED AIR FROM REAR
KTCS parts (retarder hydraulic Bleeding air from KTCS circuit BRAKE CIRCUIT (FOR MACHINE WITH
piping or harness, sensor, KTCS)
etc.)
In these case of machine with PROCEDURE TO SET BY PAYLOAD
payload meter Correction of inclination sensor METER SETTING (INCLINATION ANGLE
q Adjusting suspension cyl- SEN COMPENSATION)
inder gas pressure and oil
level See "Method for performing calibration" in
Performance of calibration of payload meter
q Replacing angle pitch sen- Operation and Maintenance Manual.
sor
q Replacing suspension
pressure sensor PROCEDURE TO SET BY PAYLOAD
q Machine without load External display lamp setting METER SETTING (SETTING OF RANGE
changes by 100 kg or more OF EXTERNAL LAMPS)
due to modification
DEFAULT SETTING OF KOMTRAX Plus ADJUST WHEN KOMTRAX Plus
CONTROLLER CONTROLLER IS REPLACED
PROCEDURE TO SET KOMTRAX Plus
LAN cable disconnect detection setting SETTING WITH THE DEFAULT SETTINGS
MENU
PROCEDURE TO SET BY PAYLOAD
Correction of inclination sensor METER SETTING (INCLINATION ANGLE
Replacement of KOMTRAX SEN COMPENSATION)
Plus controller
See "Method for performing calibration" in
Performance of calibration of payload meter
Operation and Maintenance Manual.
PROCEDURE FOR STARTING UP
Start of the KOMTRAX terminal operation
KOMTRAX TERMINAL
record
SYSTEMS)
Replacement of KOMTRAX PROCEDURE FOR STARTING UP
Start of the KOMTRAX terminal operation
terminal KOMTRAX TERMINAL
Setting default of wireless LAN modem and
Replacement of wireless LAN ADJUST WHEN WIRELESS LAN MODEM
checking of wireless LAN modem
modem IS REPLACED
communication
30-180 HD465-8, HD605-8

30 TEST AND ADJUST SET AND ADJUST EACH EQUIPMENT

When the data download
method of the KOMTRAX Plus PROCEDURE TO SET KOMTRAX Plus
controller is changed (wireless LAN cable disconnect detection setting SETTING WITH THE DEFAULT SETTINGS
LAN specification/ground level MENU
download specification)
Rearview monitor initialization PROCEDURE TO SET REARVIEW
Rearview monitor replacement MONITOR SETTINGS WITH DEFAULT
Guide line position adjustment SETTING MENU
Rearview camera PROCEDURE TO SET REARVIEW
replacement, disassembly, or Guide line position adjustment MONITOR SETTINGS WITH DEFAULT
assembly SETTING MENU
SELECT)
Replacement of the ABS PROCEDURE TO SET WITH DEFAULT
controller SETTING MENU (OPTION SELECTION)
record
SYSTEMS)
PROCEDURE TO BLEED AIR FROM
FRONT BRAKE CIRCUIT (FOR MACHINE
Replacement or WITH ABS)
disassembly/assembly of ABS PROCEDURE TO BLEED AIR FROM REAR
Bleeding air from ABS circuit
parts (retarder hydraulic piping BRAKE CIRCUIT (FOR MACHINE WITH
or harness, sensor, etc.) ABS/WITHOUT KTCS) or PROCEDURE TO
BLEED AIR FROM REAR BRAKE CIRCUIT
(FOR MACHINE WITH ABS/KTCS)
Additional installation of option PROCEDURE TO SET WITH DEFAULT
components SETTING MENU (OPTION SELECTION)
*1: Perform when necessary.
HD465-8, HD605-8 30-181

SET AND OPERATE OF MACHINE MONITOR 30 TEST AND ADJUST
SET AND OPERATE OF MACHINE MONITOR
Machine monitor
(a): Multi-information display
(b): Meter unit
(c): LED unit
REMARK
q Battery voltage may decrease suddenly and machine monitor display disappears when engine is started because of ambi-
ent temperature or battery condition. This may occur during self-check of the secondary steering. But this event does not
indicate that machine monitor is defective.
q If the start switch passes the OFF position during the manual heat operation, only the meter unit will start again (the engine
tachometer pointer makes a round travel and the speedometer shows "88"). This is not a problem.
Switch panel
0: Defroster switch/Numeral 0 input switch
1: Air conditioner switch (fan speed raise switch)/Numeral 1 input switch
2: Air conditioner switch (temperature setting raise switch)/Numeral 2 input switch
3: Air conditioner switch (auto switch)/Numeral 3 input switch
4: Air conditioner switch (fan speed lower switch)/Numeral 4 input switch
5: Air conditioner switch (temperature setting lower switch)/Numeral 5 input switch
6: Air conditioner (ON) switch/ Numeral 6 input switch
30-182 HD465-8, HD605-8

30 TEST AND ADJUST SET AND OPERATE OF MACHINE MONITOR
7: FRESH/RECIRC air selector switch/Numeral 7 input switch

8: Vent selector switch/Numeral 8 input switch
9: Air conditioner (OFF) switch/ Numeral 9 input switch
10: UP switch
11: DOWN switch
12: RETURN switch
13: ENTER switch
14: MENU switch (Operator mode) switch
REMARK
q In the user menu and service menu, only the switches shown at the bottom of multi-information display and the number
input switches are in operation.
q Each switch has the function indicated by the icon and the function to input number.
q The machine monitor automatically judges which function of each switch is active according to the screen display of the
multi-information display (a).
Operator mode and service mode of machine monitor
Machine monitor has operator mode and service mode. Different information is shown on multi-information display (a).
Some information is shown automatically according to the configuration of the machine monitor and the others are shown ac-
cording to the operation with switches.
q Operator mode
The information items in this mode are normally shown. The operator can show and set them by the operation with switch-
es. (Display and setting of some items need special operation of switches.)
For details, see Operation and Maintenance Manual.
Operator mode
Display of KOMATSU logo
Display of password input
Display of maintenance due time over
Display of standard screen
Display of end screen
Display of engine shutdown secondary switch operation
Operation of air conditioner
Check of maintenance information
Setting and display of user mode (including KOMTRAX messages for users)
Display of ECO guidance
Setting of machine body operation
Display of aftertreatment devices regeneration
Display function of action level and failure code
Follow these functions become operational when you perform special operations.
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN

DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN
EXAMINE FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)
EXAMINE FUNCTION OF SERVICE METER AND ODOMETER
USAGE LIMITATION AND CHANGE MAINTENANCE PASSWORD
METHOD TO SET TRAVEL SPEED LIMIT (FOR MACHINE WITH MAXIMUM SPEED LIMIT FUNCTION)
HD465-8, HD605-8 30-183

q Service Mode
The information items in this mode are not normally shown. Technicians can operate the specific switches to change dis-
play and settings. This mode is used to test, adjust, or troubleshoot.
Service Mode
PROCEDURE TO CHECK PRE-DEFINED MONITOR INFORMATION
PROCEDURE TO EXAMINE SELF-DEFINE MONITOR INFORMATION
PROCEDURE TO CERTIFY ABNORMALITY RECORD (MECHANICAL SYSTEMS)
PROCEDURE TO CERTIFY ABNORMALITY RECORD (ELECTRICAL SYSTEMS)
PROCEDURE TO CONFIRM MAINTENANCE RECORD
PROCEDURE TO OPERATE MAINTENANCE MODE SETTING
PROCEDURE FOR OPERATING PHONE NUMBER ENTRY SETTING
PROCEDURE TO SET WITH DEFAULT SETTING MENU (MACHINE MODEL SELECT)
PROCEDURE TO SET WITH DEFAULT SETTING MENU (OPTION SELECTION)
PROCEDURE FOR SETTING WITH DEFAULT SETTING MENU (UNIT)
PROCEDURE TO SET REARVIEW MONITOR SETTINGS WITH DEFAULT SETTING MENU
PROCEDURE TO SET KOMTRAX Plus SETTING WITH THE DEFAULT SETTINGS MENU
PROCEDURE TO SET AUTO-IDLE STOP TIMER SETTING WITH THE DEFAULT SETTING MENU (*1)
PROCEDURE TO OPERATE CYLINDER CUT-OUT OPERATION TESTS
PROCEDURE TO OPERATE REGENERATION FOR SERVICE TEST MENU
PROCEDURE TO OPERATE THE TEST MENU (KDPF MEMORY RESET)
OPERATE ENGINE CONTROLLER ACTIVE FAULT CLEAR TEST MENU
PROCEDURE TO OPERATE ASH IN SOOT ACCUMULATION CORRECTION TEST MENU
PROCEDURE TO ADJUST ECMV AUTOMATIC COMPENSATION WITH ADJUSTMENT MENU
PROCEDURE TO ADJUST T/M INITIAL LEARNING WITH ADJUSTMENT MENU
PROCEDURE TO ADJUST T/M INITIAL LEARNING RESET WITH ADJUSTMENT MENU
PROCEDURE TO ADJUST (ENGINE MODE FIXING)
PROCEDURE TO ADJUST (FAN MODE FIXING)
PROCEDURE TO ADJUST (S/T PUMP SWASH PLATE FIXING)
PROCEDURE TO ADJUST (THROTTLE LIMIT CHECK)
PROCEDURE TO ADJUST WITH ADJUSTMENT MENU (KTCS SYSTEM CHECK)
PROCEDURE TO ADJUST WITH ADJUSTMENT MENU (RETARDER HOIST CONTROLLER MEMORY RESET)
PROCEDURE TO ADJUST WITH ADJUSTMENT MENU (KTCS VALVE SETTING)
PROCEDURE TO CRANK WITH NO-INJECTION
PROCEDURE TO SET BY PAYLOAD METER SETTING (SETTING OF LOADING START PAYLOAD)
PROCEDURE TO SET BY PAYLOAD METER SETTING (SETTING OF LOADING END TRAVEL DIST)
PROCEDURE TO SET BY PAYLOAD METER SETTING (PAYLOAD OFFSET)
PROCEDURE TO SET BY PAYLOAD METER SETTING (PAYLOAD CALCULATION METHOD)
PROCEDURE TO SET BY PAYLOAD METER SETTING (PAYLOAD CALCULATION COMPENSATION)
PROCEDURE TO SET BY PAYLOAD METER SETTING (INCLINATION ANGLE SEN COMPENSATION)
PROCEDURE TO SET BY PAYLOAD METER SETTING (SETTING OF RANGE OF EXTERNAL LAMPS)
30-184 HD465-8, HD605-8

Service Mode
PROCEDURE FOR MANUAL SNAP SHOT
PROCEDURE TO CONFIRM KOMTRAX SETTINGS (TERMINAL STATUS)
PROCEDURE TO CONFIRM KOMTRAX SETTINGS (GPS AND COMMUNICATION STATUS)
PROCEDURE TO CONFIRM KOMTRAX SETTINGS (MODEM STATUS)
PROCEDURE TO DISPLAY SERVICE MESSAGE
*1: Function is available when the auto idle stop (optional) is installed.
HD465-8, HD605-8 30-185

OPERATOR MODE
These items require specified switch operation in operator mode.
For details of contents and operations of each function and display, see "STRUCTURE AND FUNCTION", or the "Operation
and Maintenance Manual".
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN
When the operator identification function is active, turn the start
switch to ON position while you push DOWN switch (11), and the fol-
lowing technician identification state screen is shown for 2 seconds.
REMARK
The operator identification function display lets the owner select be-
tween the operation performed by technician (maintenance work)
and the operation performed by operator. It is of benefit in manage-
ment of operating state by operator, fuel consumption, machine trou-
ble.
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN

After showing the technician identification condition screen, the operator ID input screen is shown.
q The screen shown in the figure is displayed only when the oper-
ator ID number input setting is active.
q Before you perform examine and adjust, make sure that the input
setting of ID are completed for the operator identification function
by the owner.
q When the owner input the ID setting with SKIP, push MENU
switch (14) after displaying the technician identification state
screen, and the engine will start.
q When the owner input the ID setting without SKIP, the engine will
not start. In such a case, request a person on the owner side who
is in charge of the machine for the registered ID.
30-186 HD465-8, HD605-8

q Make sure that the identification of the technician is not neces-

sary with the administrator of the machine before you start. This
switch operation is not necessary when you turn the start switch
to ON position.
Program the ID, and push MENU switch (14), and make sure be-
fore start screen appears.
EXAMINE FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)

While the standard screen is shown, if switches on the switch panel
are operated in the this manner, all the LCD screen turns white.
Switch operation: Push UP switch (10) while you hold DOWN switch
(11) and release UP switch (10).
q If there is a display error in the LCD, only that part is indicated in
black.
q An LCD panel, as one of its properties, shows black marks
(marks that remain unlit) and bright marks (marks that do not go
off).
If the bright marks or the black marks are fewer than 10, it does
not indicate that the LCD panel is defective.
q To go back to the former screen, push any one of the switches
(10) to (14).
HD465-8, HD605-8 30-187

EXAMINE FUNCTION OF SERVICE METER AND ODOMETER

When you examine the service meter and odometer with the start
switch in OFF position, operate switches on the switch panel as fol-
lows to show the service meter and odometer section.
Switch operation: Push UP switch (10) (concurrently) while you push
DOWN switch (11).
REMARK
q There is some time delay with the start of the LCD. Hold down
the switches until the service meter is shown.
q If you release one of the switches, Up switch (10) or Down switch
(11), the multi-information display goes off.
q After a long time usage, blue points (points that remain lit) may
appear on LCD screen. it does not indicate that the LCD panel is
defective.
USAGE LIMITATION AND CHANGE MAINTENANCE PASSWORD

Password setting can be done on the machine monitor for a user limitation setting. After setting the password, a password enter
screen is shown when resetting the maintenance items.
Perform the usage limitation setting and password setting according to the following procedure.
Setting usage limitation (password)
1. After the standard screen is shown, use a switch on the monitor
panel to perform this operation:
Switch operation: Push the numeral input switch (5) 3 times while
you hold DOWN switch (11) (push the two switches simultane-
ously).
REMARK
This switch operation is available after a lapse of 10 minutes after
the start switch is turned to ON position.
30-188 HD465-8, HD605-8

2. After the "Usage Limitation Password" screen is shown, use a

switch on the switch panel to input and validate the current pass-
word.
RETURN switch (12): Deletes an input numeric/Returns to the
standard screen
ENTER switch (13): Validates the inputted password
Numerical input switch (15): Enters a numerical value
REMARK
q Default password: 000000
q When the password entry is correct, the screen changes to
the next screen.
q When the password entry is incorrect, a message to request
password entry again is shown.
q The password for the usage limitation and the engine start
lock password are the same in default setting.
3. After the "Usage Limitation Setting" screen is shown, use a

switch on the switch panel to select and validate "Usage Limita-
tion ON or OFF".
UP switch (10): Moves the selection up by one item
DOWN switch (11): Moves the selection down by one item
RETURN switch (12): Cancels the selection and returns to the
previous screen
ENTER switch (13): Validates the selection
HD465-8, HD605-8 30-189

4. After the "Usage Limitation ON or OFF" screen is shown, use a

switch on the switch panel to select and validate "ON/OFF".
OFF: Password enter screen is not shown
ON: Shows the password enter screen for resetting of mainte-
nance items
previous screen
Change password
1. After the "Usage Limitation New Password Input" screen is
shown, use a switch on the switch panel to input and validate a
new password.
RETURN switch (12): Clears an input numeric/ Returns to the
previous screen
REMARK
q For details of changing password, see "Password setting and
canceling manual".
the next screen.
q Set a new password of 4 to 6 numerical digits. (A password
with 3 or less digits or 7 or more digits are not allowed).
30-190 HD465-8, HD605-8

2. After the "Usage Limitation New Password Input" screen is

shown again, use a switch on the switch panel to input and vali-
date a new password.
standard screen
REMARK
If the password input is different from the one before, a message
is shown and requests you to input password again.
If the "Usage Limitation Setting" screen is shown after the screen

to notify completion of setting is shown, the password is changed
successfully.
HD465-8, HD605-8 30-191

METHOD TO SET TRAVEL SPEED LIMIT (FOR MACHINE WITH MAXIMUM SPEED LIMIT
FUNCTION)
NOTICE
Do not share the procedure to set the machine speed limit with anyone except an authorized person who can decide
the speed limit.
Use "Vehicle Speed Limit Function" to change the different settings of the maximum speed limit function setting.
The "Vehicle Speed Limit Function" can change the settings of the "Travel Speed Limit with No Load Setting", "Travel
Speed Limit with Load Setting", and the password for the "Vehicle Speed Limit Function".
PROCEDURE TO SHOW TRAVEL SPEED LIMIT (FOR MACHINE WITH MAXIMUM SPEED
LIMIT FUNCTION)
1. While the standard screen (operator mode) is shown, use a
switch on the monitor panel to perform the following operation:
Switch operation: Hold DOWN switch (11), sequentially push (1),
(5), (9), (1), (5), and (9) of numeral input switches.
REMARK
q This switch operation is available 10 minutes after the start
switch is turned to ON position.
q If the option setting of the maximum speed limit function set-
ting is deactivated or the communication error occurs, "Vehi-
cle Speed Limit Function" is not shown.
2. After the "Password?" screen is shown, use a switch on the

switch panel to input and validate the current password.
standard screen
REMARK
the next screen.
q When the password entry is incorrect three times in a row,
you cannot enter the password for five minutes.
Enter the password again after five minutes or more.
30-192 HD465-8, HD605-8

3. When the "Vehicle Speed Limit Function" screen is shown, the

vehicle speed limit function is selected. Select an each menu you
use with switches on the switch panel.
RETURN switch (12): Returns to the standard screen (operator
mode)
PROCEDURE TO SET TRAVEL SPEED LIMIT WHEN THE MACHINE IS LOADED (FOR
MACHINE WITH MAXIMUM SPEED LIMIT FUNCTION)
1. When the standard screen (operator mode) is shown, choose the
"Vehicle Speed Limit Function" screen.
REMARK
For the displaying method, see "PROCEDURE TO SHOW
TRAVEL SPEED LIMIT".
2. When the "Vehicle Speed Limit Function" screen is shown, use a
switch on the switch panel to select "Travel Speed Limit with
Load Setting".
mode)
HD465-8, HD605-8 30-193

3. When the "Travel Speed Limit with Load Setting" screen is shown,
use a switch on the switch panel to set the vehicle speed limit.
UP switch (10): Increases the set speed by 1 km/h
Hold the switch to continuously increase the speed.
DOWN switch (11): Decreases the set speed by 1 km/h
Hold the switch to continuously decrease the speed.
RETURN switch (12): Returns to the "Vehicle Speed Limit Func-
tion" screen
ENTER switch (13): Validates the set value and moves to the
next screen
REMARK
q The range of the machine speed limit with load setting is from
20 km/h to the machine speed limit with no load setting.
q When the set speed is beyond the range, you cannot set this
function.
4. When the "Do you want to set a travel speed limit?" screen is
shown, push ENTER switch (13) to validate the setting.
RETURN switch (12): Cancels the setting and returns to the "Ve-
hicle Speed Limit Function" screen
Enter switch (13): Accepts the setting
REMARK
q The "Setting Completed" is shown by pushing ENTER switch
(13) to validate the change.
q The display goes back to the "Vehicle Speed Limit Function"
screen when RETURN switch (12) is pushed after the "Set-
ting Completed" is shown.
30-194 HD465-8, HD605-8

PROCEDURE TO SET TRAVEL SPEED LIMIT WHEN THE MACHINE IS NOT LOADED
(FOR MACHINE WITH MAXIMUM SPEED LIMIT FUNCTION)
REMARK

switch on the switch panel to select "Travel Speed Limit with No
Load Setting".
mode)
HD465-8, HD605-8 30-195

3. When the "Travel Speed Limit with No Load Setting" screen is

shown, use a switch on the switch panel to set the vehicle speed
limit.
UP switch (10): Increases the set speed by 1 km/h
Hold the switch to continuously increase the speed.
DOWN switch (11): Decreases the set speed by 1 km/h
Hold the switch to continuously decrease the speed.
RETURN switch (12): Returns to the "Vehicle Speed Limit Func-
tion" screen
ENTER switch (13): Validates the set value and moves to the
next screen
REMARK
q The range of the machine speed limit with no load setting is
from the machine speed limit with load setting to 78 km/h.
q When the set speed is beyond the range, you cannot set this
function.
4. When the "Do you want to set a travel speed limit?" screen is
shown, push ENTER switch (13) to validate the setting.
RETURN switch (12): Cancels the setting and returns to the "Ve-
hicle Speed Limit Function" screen
Enter switch (13): Accepts the setting
REMARK
q The "Setting Completed" is shown by pushing ENTER switch
(13) to validate the change.
q The display goes back to the "Vehicle Speed Limit Function"
screen when RETURN switch (12) is pushed after the "Set-
ting Completed" is shown.
30-196 HD465-8, HD605-8

PROCEDURE TO CHANGE THE PASSWORD OF THE TRAVEL SPEED LIMIT

REMARK

switch on the switch panel to select "Change Password".
mode)
3. When the "Change Password" screen is shown, use a switch on

the switch panel to input and validate a new password.
RETURN switch (12): Clears an input numeric/Returns to the
"Vehicle Speed Limit Function" screen
REMARK
q Set a new password of 4 to 6 numerical digits.
(A password with 3 or less digits or 7 or more digits are not
allowed).
HD465-8, HD605-8 30-197

4. After the "Please Enter New Password." is shown again, use a

switch on the switch panel to input and validate a new password.
RETURN switch (12): Clears an input numeric/Returns to the
"Vehicle Speed Limit Function" screen
REMARK
If the password input is different from the one before, a message
is shown and requests you to input password again.
After "New password accepted" is shown, the password change
is complete when the "Vehicle Speed Limit Function" is shown.
30-198 HD465-8, HD605-8

SERVICE MODE
PROCEDURE TO OPERATE SERVICE MODE
To change the mode of the machine monitor to the service mode from the operator mode, perform the following operation.
This operation is always required when you use the service mode.
1. While the standard screen is shown, use a switch on the monitor
panel to perform the following operation:
Switch operation: While you push Down switch (11), push down
in sequence (1), (2), and (3) of numeral input switches.
REMARK
Switching operation in the service mode is effective only while
the standard screen is shown.
2. When the "Service Menu" screen is shown, the service mode is

selected. Select a service menu you use with switches on the
monitor panel.
mode)
REMARK
q Input a code (2-digit) with numeral input switch (15) to directly
select the menu, and then push ENTER switch (13) to enter
the selection.
q Items with 2-digit codes are the menus shown on the "Service
Menu" screen. The items on the right are the menus on the
next hierarchy.
This shows the items you can select with "Service Menu" (which
include some items which have a special switch operation).
Select items on "Service Menu"
Code Item Reference

01 Pre-defined Monitoring PROCEDURE TO CHECK PRE-DEFINED MONITOR INFORMATION
02 Self-define Monitoring PROCEDURE TO EXAMINE SELF-DEFINE MONITOR INFORMATION
HD465-8, HD605-8 30-199

Code Item Reference

Mechanical Sys PROCEDURE TO CERTIFY ABNORMALITY RECORD (MECHANICAL
Abnormality Abnormality Record SYSTEMS)
03
Record Electrical Sys Abnormality PROCEDURE TO CERTIFY ABNORMALITY RECORD (ELECTRICAL
Record SYSTEMS)
04 Maintenance Record PROCEDURE TO CONFIRM MAINTENANCE RECORD
05 Maintenance Mode Setting PROCEDURE TO OPERATE MAINTENANCE MODE SETTING
06 Phone Number Entry PROCEDURE FOR OPERATING PHONE NUMBER ENTRY SETTING
PROCEDURE TO SET WITH DEFAULT SETTING MENU (MACHINE
Machine Model Select
MODEL SELECT)
PROCEDURE TO SET WITH DEFAULT SETTING MENU (OPTION
Option Selection
SELECTION)
PROCEDURE FOR SETTING WITH DEFAULT SETTING MENU
Unit Selection
(UNIT)
07 Default
PROCEDURE TO SET REARVIEW MONITOR SETTINGS WITH
Rearview Monitor Setting
DEFAULT SETTING MENU
PROCEDURE TO SET KOMTRAX Plus SETTING WITH THE
KOMTRAX Plus Setting
DEFAULT SETTINGS MENU
Auto Idle Stop Timer PROCEDURE TO SET AUTO-IDLE STOP TIMER SETTING WITH THE
Fixing (*1) DEFAULT SETTING MENU
Cylinder Cutout Mode PROCEDURE TO OPERATE CYLINDER CUT-OUT OPERATION
Operation TESTS
Active Regeneration for PROCEDURE TO OPERATE REGENERATION FOR SERVICE TEST
Service MENU
Diagnostic PROCEDURE TO OPERATE THE TEST MENU (KDPF MEMORY
08 KDPF Memory Reset
Tests RESET)
Engine Controller Active OPERATE ENGINE CONTROLLER ACTIVE FAULT CLEAR TEST
Fault Clear MENU
Ash in Soot Accumulation PROCEDURE TO OPERATE ASH IN SOOT ACCUMULATION
Correction CORRECTION TEST MENU
ECMV Automatic PROCEDURE TO ADJUST ECMV AUTOMATIC COMPENSATION
Compensation WITH ADJUSTMENT MENU
PROCEDURE TO ADJUST T/M INITIAL LEARNING WITH
T/M Initial Learning
ADJUSTMENT MENU
PROCEDURE TO ADJUST T/M INITIAL LEARNING RESET WITH
T/M Initial Learning Reset
ADJUSTMENT MENU
Engine Mode Fixing PROCEDURE TO ADJUST (ENGINE MODE FIXING)
Fan Mode Fixing PROCEDURE TO ADJUST (FAN MODE FIXING)
09 Adjustment S/T Pump Swash Plate
Fixing
Throttle Limit Check PROCEDURE TO ADJUST (THROTTLE LIMIT CHECK)
PROCEDURE TO ADJUST WITH ADJUSTMENT MENU (KTCS
KTCS Check
SYSTEM CHECK)
Retarder and Hoist PROCEDURE TO ADJUST WITH ADJUSTMENT MENU (RETARDER
Controller Memory Reset HOIST CONTROLLER MEMORY RESET)
PROCEDURE TO ADJUST WITH ADJUSTMENT MENU (KTCS VALVE
KTCS Valve Fixing
SETTING)
30-200 HD465-8, HD605-8

Code Item Reference

10 No-Injection Cranking PROCEDURE TO CRANK WITH NO-INJECTION
Setting of Loading Start PROCEDURE TO SET BY PAYLOAD METER SETTING (SETTING OF
Payload LOADING START PAYLOAD)
Setting of Loading End PROCEDURE TO SET BY PAYLOAD METER SETTING (SETTING OF
Travel Dist. LOADING END TRAVEL DIST)
PROCEDURE TO SET BY PAYLOAD METER SETTING (PAYLOAD
Payload offset
OFFSET)
Payload
Payload Calculation PROCEDURE TO SET BY PAYLOAD METER SETTING (PAYLOAD
11 Meter
Procedure CALCULATION METHOD)
Setting
Payload Calculation PROCEDURE TO SET BY PAYLOAD METER SETTING (PAYLOAD
Compensation CALCULATION COMPENSATION)
Inclination Angle Sen PROCEDURE TO SET BY PAYLOAD METER SETTING
Compensation (INCLINATION ANGLE SEN COMPENSATION)
Setting of Range of PROCEDURE TO SET BY PAYLOAD METER SETTING (SETTING OF
External Lamps RANGE OF EXTERNAL LAMPS)
12 Manual Snap Shot PROCEDURE FOR MANUAL SNAP SHOT
PROCEDURE TO CONFIRM KOMTRAX SETTINGS (TERMINAL
Terminal Setting State
STATUS)
KOMTRAX
GPS & Communication PROCEDURE TO CONFIRM KOMTRAX SETTINGS (GPS AND
13 Setting
State COMMUNICATION STATUS)
Display
PROCEDURE TO CONFIRM KOMTRAX SETTINGS (MODEM
Modem Information
STATUS)
14 Service Message PROCEDURE TO DISPLAY SERVICE MESSAGE
*1: Function is available when the auto idle stop (optional) is installed.
PROCEDURE TO CHECK PRE-DEFINED MONITOR INFORMATION

The machine monitor can monitor the condition of the machine in real time. The monitor receives signals from switches, sen-
sors, and actuators installed to different parts of the machine and the information from the controllers.
In "Pre-defined Monitoring", frequently used monitoring items are selected before, which are useful for Pm clinic test and trou-
bleshooting.
1. Select "Pre-defined Monitoring" on the "Service Menu" screen.
HD465-8, HD605-8 30-201

2. When the "Pre-defined Monitoring" screen is shown, use a

switch on the switch panel to select the page (screen), and
examine it.
UP switch (10): Returns to the previous page (screen)
DOWN switch (11): Moves to the next page (screen)
RETURN switch (12): Returns to the "Service Menu" screen
MENU switch (14): Switches between the Hold and the Release
(If the Hold is selected, "HOLD" part is hatched.)
(a): Monitoring information
(b): Shift indicator
(c): Engine coolant temperature
(d): Torque converter oil temperature
(e): Hydraulic oil temperature
(f): Fuel level
(g): Current pages (screens)/Total pages (screens)
REMARK
For the items not shown in "Pre-defined Monitoring", you can se-
lect and examine from "Self-define Monitoring" items.
30-202 HD465-8, HD605-8

TABLE OF PRE-DEFINED MONITORING ITEMS

This section shows the Pre-defined Monitoring items shown when all the options are equipped.
Pre-defined Monitoring (01/28), machine basic relation (1)
Unit Relevant
No. Monitoring code Table of self-define monitoring (Displayed on screen)
SI Non SI component
1 01002 Engine Speed r/min rpm ENG

2 04107 Coolant Temperature ˚C ˚F ENG
3 37200 Engine Oil Pressure kPa psi ENG
4 30100 T/C Oil Temperature ˚C ˚F T/M
5 30216 Retarder Oil Temperature (Gauge) ˚C ˚F MON
6 32701 S/T Oil Temperature ˚C ˚F RHC
Pre-defined Monitoring (02/28), machine basic relation (2)
Unit Relevant
SI Non SI component

2 32500 T/M Oil Temperature ˚C ˚F T/M
3 55001 A/C Fresh Air Temperature ˚C ˚F MON
4 04307 Battery Charge Voltage (T/M Con) V V T/M
5 03208 Source Voltage (T/M Controller) V V T/M
Pre-defined Monitoring (03/28), fuel injection relation
Unit Relevant
SI Non SI component

2 36400 Rail Pressure MPa psi ENG
3 36200 Rail Pressure Command MPa psi ENG
4 17201 PCV Close Timing (TDC Standard) CA CA ENG
Pre-defined Monitoring (04/28), EGR, VGT actuator relation
Unit Relevant
SI Non SI component

2 48100 Turbocharger Speed r/min rpm ENG
3 18100 EGR Valve Position mm in ENG
4 48600 EGR Solenoid Current mA mA ENG
5 48700 VGT Position mm in ENG
6 48800 VGT Solenoid Current mA mA ENG
HD465-8, HD605-8 30-203

Pre-defined Monitoring (05/28), engine temperature relation
Unit Relevant
SI Non SI component

4 18400 Intake Temperature ˚C ˚F ENG
5 18500 Charge Temperature ˚C ˚F ENG
6 42700 Engine Oil Temperature ˚C ˚F ENG
Pre-defined Monitoring (06/28), intake and exhaust pressure relation (1)
Unit Relevant
SI Non SI component

3 37400 Ambient Pressure kPa psi ENG
4 36500 Charge Pressure kPa psi ENG
6 48200 MAF kg/min lb/min ENG
Pre-defined Monitoring (07/28), intake and exhaust pressure relation (2)
Unit Relevant
SI Non SI component
1 01004 Engine Speed_2 r/min rpm ENG

2 37400 Ambient Pressure kPa psi ENG
Pre-defined Monitoring (08/28), engine aftertreatment relation (1)
Unit Relevant
SI Non SI component
1 47300 KDOC 1 Inlet Temperature ˚C ˚F ENG

2 47400 KDOC 1 Outlet Temperature ˚C ˚F ENG
3 47200 KDPF 1 Outlet Temperature ˚C ˚F ENG
4 47000 KDPF Outlet Pressure kPa psi ENG
5 47100 KDPF Differential Pressure kPa psi ENG
6 47600 Dosing Fuel Pressure kPa psi ENG
30-204 HD465-8, HD605-8

Pre-defined Monitoring (09/28), engine aftertreatment relation (2)
Unit Relevant
SI Non SI component
1 47302 KDOC 1 Inlet Temperature_2 ˚C ˚F ENG

2 47402 KDOC 1 Outlet Temperature_2 ˚C ˚F ENG
3 47202 KDPF 1 Outlet Temperature_2 ˚C ˚F ENG
4 47002 KDPF Outlet Pressure_2 kPa psi ENG
5 47102 KDPF Differential Pressure_2 kPa psi ENG
6 47602 Dosing Fuel Pressure_2 kPa psi ENG
Pre-defined Monitoring (10/28), engine output command relation
Unit Relevant
SI Non SI component

2 31701 Throttle Position % % ENG
3 36000 Throttle Adjustment Command % % T/M
4 44201 Throttle Lower Limit Command % % T/M
5 44200 Throttle Higher Limit Command % % T/M
6 17302 Dynamic Torque Command % % T/M
Pre-defined Monitoring (11/28), transmission shaft relation
Unit Relevant
SI Non SI component

2 31200 T/M Input Shaft Speed r/min rpm T/M
3 31300 T/M Intermediate Shaft Speed r/min rpm T/M
4 31400 T/M Output Shaft Speed r/min rpm T/M
Pre-defined Monitoring (12/28), transmission valve relation (1)
Unit Relevant
SI Non SI component

2 30100 T/C Oil Temperature ˚C ˚F T/M
3 32600 T/C Oil Pressure MPa psi T/M
4 07701 Main Flow Selector Valve Press MPa psi T/M
5 07707 Main Press Variable Valve Press MPa psi T/M
6 95001 Lockup State ON/OFF ON/OFF T/M
HD465-8, HD605-8 30-205

Pre-defined Monitoring (13/28), transmission valve relation (2)
Unit Relevant
SI Non SI component
1 07701 Main Flow Selector Valve Press MPa psi T/M

2 31644 Main Flow Selector Valve Current mA mA T/M
3 07707 Main Press Variable Valve Press MPa psi T/M
4 31643 Main Press Variable Sol Current mA mA T/M
Pre-defined Monitoring (14/28), radiator fan relation
Unit Relevant
SI Non SI component

3 32701 S/T Oil Temperature ˚C ˚F RHC
4 10007 Radiator Fan Speed Command r/min rpm T/M
5 10009 Radiator Fan Speed r/min rpm T/M
6 41400 Radiator Fan Pump EPC Current mA mA T/M
Pre-defined Monitoring (15/28), machine lock-out relation
Unit Relevant
SI Non SI component
Machine Lockout SW1

1 41022 T/M Controller SW Input 3 ON/OFF ON/OFF T/M
Machine Lockout SW2
2 91908 Parking Brake Pressure (Rear) MPa psi RHC
Transmission Controller Steering Lockout Sol.

4 41023 ON/OFF ON/OFF T/M
Output 1 STR/Hoist Lockout Sol.
5 95302 S/T Pressure MPa psi RHC
6 95307 STR/Hoist Oil Pressure MPa psi T/M
Pre-defined Monitoring (16/28), retarder relation
Unit Relevant
SI Non SI component
1 33900 Retarder Lever Potentio Voltage V V RHC

2 91910 Retarder Pressure (Rear) MPa psi RHC
3 33806 Retarder EPC Solenoid Current(R) mA mA RHC
30-206 HD465-8, HD605-8

Pre-defined Monitoring (17/28), ARSC relation
Unit Relevant
SI Non SI component

3 30215 Retarder Oil Temperature (Rear) ˚C ˚F RHC
4 33806 Retarder EPC Solenoid Current(R) mA mA RHC
Pre-defined Monitoring (18/28), KTCS relation(1)
Unit Relevant
SI Non SI component

3 35402 S/T Angle deg deg RHC
4 39704 Wheel Speed (Rear Right) r/min rpm RHC
5 39705 Wheel Speed (Rear Left) r/min rpm RHC
Pre-defined Monitoring (19/28), KTCS relation(2)
Unit Relevant
SI Non SI component

2 49004 KTCS Pressure (Rear Left) MPa psi RHC
3 49008 KTCS EPC Solenoid Current (R L) mA mA RHC
4 49006 KTCS Pressure (Rear Right) MPa psi RHC
5 49009 KTCS EPC Solenoid Current (R R) mA mA RHC
Pre-defined Monitoring (20/28), hoist relation
Unit Relevant
SI Non SI component
1 34304 Hoist Lever Potentio Volt (Main) V V RHC

2 34305 Hoist Lever Potentio Volt (Sub) V V RHC
3 34602 Body Positioner Sensor Voltage V V RHC
4 45601 Hoist EPC Solenoid Current mA mA RHC
Hoist Selector Solenoid ON/OFF ON/OFF RHC
5 40985 Hoist Control Output 1 Kick out Solenoid ON/OFF ON/OFF RHC
S/T Pump Select Solenoid ON/OFF ON/OFF RHC
HD465-8, HD605-8 30-207

Pre-defined Monitoring (21/28), secondary steering relation
Unit Relevant
SI Non SI component

3 95302 S/T Pressure MPa psi RHC
4 07703 Secondary S/T Pressure MPa psi RHC
Secondary S/T Control
5 40986 2ndary S/T Motor Relay ON/OFF ON/OFF RHC
Output 1
Pre-defined Monitoring (22/28), parking brake relation
Unit Relevant
SI Non SI component
1 35500 Accumulator Oil Pressure Sensor (Front) MPa psi RHC

2 35501 Accumulator Oil Pressure Sensor (Rear) MPa psi RHC
3 91917 Secondary Brake Pressure MPa psi RHC
5 40987 RHC Input 1 Parking Brake Sol State ON/OFF ON/OFF RHC
6 40988 Monitor Output Parking Brake SW Lamp ON/OFF ON/OFF MON
Pre-defined Monitoring (23/28), automatic suspension relation
Unit Relevant
SI Non SI component
1 40000 Travel Speed (Speedometer) km/h MPH MON

2 35403 S/T Speed rad/sec rad/sec RHC
3 32814 Suspension Pressure (Rear Left) MPa psi RHC
4 32816 Suspension Pressure (Rear Right) MPa psi RHC
Auto Suspension Sol 1 ON/OFF ON/OFF RHC
5 41004 RHC Output 3
Auto Suspension Sol 2 ON/OFF ON/OFF RHC
Pre-defined Monitoring (24/28), payload meter control relation
Unit Relevant
SI Non SI component
1 42400 Machine State - - KOM PLUS

2 32901 Inclination Angle (Longitudinal) deg deg KOM PLUS
3 32803 Suspension Pressure (Front Left) MPa psi KOM PLUS
4 32804 Suspension Pressure(Front Right) MPa psi KOM PLUS
5 32807 Suspension Pressure (Rear Left) MPa psi KOM PLUS
6 32806 Suspension Pressure (Rear Right) MPa psi KOM PLUS
30-208 HD465-8, HD605-8

Pre-defined Monitoring (25/28), KOMTRAX Plus control relation
Unit Relevant
SI Non SI component

2 18500 Charge Temperature ˚C ˚F ENG
3 42602 Exhaust Air Temperature ˚C ˚F KOM PLUS
Pre-defined Monitoring (26/28), ABS (1)
Unit Relevant
SI Non SI component

2 39703 Wheel Speed (FL) r/min rpm ABS
3 39702 Wheel Speed (FR) r/min rpm ABS
4 39705 Wheel Speed (Rear Left) r/min rpm RHC
5 39704 Wheel Speed (Rear Right) r/min rpm RHC
Unit Relevant
SI Non SI component
1 43312 ABS Pressure (FL) MPa psi ABS

2 43308 ABS Solenoid Current (FL) mA mA ABS
3 43314 ABS Pressure (FR) MPa psi ABS
4 43309 ABS Solenoid Current (FR) mA mA ABS
5 41005 ABS Con. Input 1 ABS Cut Press SW (F) ON/OFF ON/OFF ABS
6 41007 ABS Con. Output ABS Cut V. (F) ON/OFF ON/OFF ABS
Unit Relevant
SI Non SI component
1 43316 ABS Pressure (RL) MPa psi ABS

2 43310 ABS Solenoid Current (RL) mA mA ABS
3 43318 ABS Pressure (RR) MPa psi ABS
4 43311 ABS Solenoid Current (RR) mA mA ABS
5 41009 ABS Con. Input 1 ABS Cut Press SW (R) ON/OFF ON/OFF ABS
6 41014 ABS Con. Output ABS Cut V. (R) ON/OFF ON/OFF ABS
HD465-8, HD605-8 30-209

PROCEDURE TO EXAMINE SELF-DEFINE MONITOR INFORMATION

The machine monitor can monitor the condition of the machine in real time. The monitor receives signals from switches, sen-
sors, and actuators installed to different parts of the machine and the information from the controllers.
"Monitoring / Custom" is used to select a desired monitoring item.
1. Select "Self-define Monitoring" on the "Service Menu" screen.
2. When the "Monitoring Selection Menu" screen is shown, use a

switch on the switch panel to select the item to be monitored.
RETURN switch (12): Clears an input value/Returns to the
"Service Menu" screen
MENU switch (14): Moves the selection to the right by one item
REMARK
q Setting of the monitoring changes to "ENG" → "KDPF" →
"T/M" → "RHC" → "ABS" → "KOM PLS" → "MON" → "ENG"
in this order when MENU switch (14) is pushed.
q To select while confirming items to monitor, select the com-
ponent in charge with MENU switch (14), select the item with
UP switch (10) or DOWN switch (11) and validate your selec-
tion with ENTER switch (13).
q To select items through entry of a monitoring code, if you in-
put a code (5 digit) by using numeral input switch (15), the tar-
get item is selected directly. So validate it by using ENTER
switch (13).
q If the color of row showing the monitoring code for the select-
ed item changes from yellow to red, the selection of the item
is entered.
q A maximum of 6 monitoring items are selectable at a time.
However, the items may not be set up to 6 depending on the
form of display of the selected item.
q The "ABS" tab is shown when ABS is equipped.
30-210 HD465-8, HD605-8

3. After you select monitoring items, use a switch on the monitor

panel to execute the monitoring.
REMARK
q To execute the monitoring, double-click or push and hold EN-
TER switch (13) (for approximately 2 seconds).
q To execute with a numeral input switch, input "99999" and
push ENTER switch (13).
q If monitoring items are selected up to the limit number, mon-
itoring is executed automatically.
q When monitoring only 2 items, select each items and validate
the selection with ENTER switch (13). And if you push EN-
TER switch (13) again after the selection, the state is
changed to monitoring being executed.
4. On the "Monitoring" screen, perform the necessary operation of

the machine and check the self-define monitoring information.
"Monitoring" screen displays the following information.
(a): Monitoring information
(b): Shift indicator
(c): Engine coolant temperature
(d): Torque converter oil temperature
(e): Hydraulic oil temperature
(f): Fuel level
REMARK
q The self-define monitoring information is indicated by value, ON/OFF, or special display.
q As a display unit, you can select "SI" or "Non SI" on "Default" screen of "Service Menu" screen.
HD465-8, HD605-8 30-211

5. Regarding monitoring information, the screen displaying

real-time data can be held or released by MENU switch (14).
RETURN switch (12): Returns to "Monitoring Selection" menu
screen
30-212 HD465-8, HD605-8

A selected monitoring item can be saved or deleted by using a

switch on the switch panel.
UP switch (10): "MEMORY" saves a monitoring item.
DOWN switch (11): "CLEAR" clears a monitoring item.
REMARK
q When a monitoring item is saved, a confirmation screen ap-
pears asking whether the saved item should be shown or not
when "Self-define Monitoring" is selected again.
q When an item is saved, it can be shown as many times as re-
quired unless it is cleared.
q If another item is saved while having the previous item saved,
the previously saved item is overwritten by the latest one.
HD465-8, HD605-8 30-213

TABLE OF SELF-DEFINE MONITOR ITEMS
Monitoring Table of self-define monitoring (Displayed on Unit Relevant

Remarks
code screen) SI Non SI component
00201 Machine ID - - ENG

20216 Engine Controller Build Version - - ENG
20217 Engine Con Calibration Data Ver - - ENG
18900 Engine Con Internal Temperature ˚C ˚F ENG
20400 Engine Controller S/N - - ENG
01002 Engine Speed r/min rpm ENG
36700 Engine Torque Ratio % % ENG
31701 Throttle Position % % ENG
03000 Throttle Position Sensor Voltage V V ENG
17500 Engine Power Mode Selection - - ENG
36400 Rail Pressure MPa psi ENG
36401 Rail Pressure Sensor Voltage V V ENG
36200 Rail Pressure Command MPa psi ENG
04107 Engine coolant temperature ˚C ˚F ENG
04105 Coolant Temperature Sensor Volt V V ENG
37200 Engine Oil Pressure kPa psi ENG
37201 Engine Oil Pressure Sensor Volt V V ENG
42700 Engine Oil Temperature ˚C ˚F ENG
42702 Engine Oil Temperature Sens Volt V V ENG
37400 Ambient Pressure kPa psi ENG
37401 Ambient Pressure Sensor Voltage V V ENG
Absolute value
display (including
36500 Charge Pressure kPa psi ENG
the ambient
pressure)
36501 Charge Pressure Sensor Voltage V V ENG
03203 Battery Power Supply V V ENG
37300 Instantaneous Fuel Consumption l/h gal/h ENG *1
31706 Final Throttle Position % % ENG
18400 Intake Temperature ˚C ˚F ENG
18401 Intake Temperature Sensor Volt V V ENG
18500 Charge Temperature ˚C ˚F ENG
18501 Charge Temperature Sensor Volt V V ENG
18100 EGR Valve Position mm in ENG
18101 EGR Valve Position Sensor Volt V V ENG
18300 Idle Validation SW 1 - - ENG
18301 Idle Validation SW 2 - - ENG
18600 Inject Fueling Command mg/st mg/st ENG
30-214 HD465-8, HD605-8


Remarks
17201 PCV Close Timing (TDC Standard) CA CA ENG

18700 Engine Output Torque Nm lbft ENG
08402 Droop SW Selection - - ENG
48400 Crankcase Pressure kPa psi ENG
48401 Crankcase Pressure Sensor Volt V V ENG
48100 Turbocharger Speed r/min rpm ENG
48200 MAF kg/min lb/min ENG
48700 VGT Position mm in ENG
48701 VGT Position Sensor Voltage V V ENG
48600 EGR Solenoid Current mA mA ENG
48800 VGT Solenoid Current mA mA ENG
48900 Engine Operation Mode - - ENG
00203 Machine ID_2 - - ENG
20219 Engine Control Program Version_2 - - ENG
20218 Engine Controller Data Version_2 - - ENG
18901 Engine Con Internal Temp_2 ˚C ˚F ENG
20401 Engine Con Internal Temp_2 - - ENG
01004 Engine Speed_2 r/min rpm ENG
03205 Battery Power Supply_2 V V ENG
47000 KDPF Outlet Pressure kPa psi KDPF
47001 KDPF Outlet Pressure Sensor Volt V V KDPF
47100 KDPF Differential Pressure kPa psi KDPF
47101 KDPF Diff Pressure Sensor Volt V V KDPF
47200 KDPF 1 Outlet Temperature ˚C ˚F KDPF
47300 KDOC 1 Inlet Temperature ˚C ˚F KDPF
47400 KDOC 1 Outlet Temperature ˚C ˚F KDPF
47500 Dosing Instant Fuel Consumption l/h gal/h KDPF
47600 Dosing Fuel Pressure kPa psi KDPF
47601 Dosing Fuel Pressure Sensor Volt V V KDPF
47700 Soot Accumulation g/L g/gal KDPF
47802 Soot Correction by Ash Influence g/L g/gal KDPF
47002 KDPF Outlet Pressure_2 kPa psi KDPF
47003 KDPF Outlet Press Sensor Volt_2 V V KDPF
47102 KDPF Differential Pressure_2 kPa psi KDPF
47103 KDPF Diff Pressure Sensor Volt_2 V V KDPF
47202 KDPF 1 Outlet Temperature_2 ˚C ˚F KDPF
47302 KDOC 1 Inlet Temperature_2 ˚C ˚F KDPF
47402 KDOC 1 Outlet Temperature_2 ˚C ˚F KDPF
HD465-8, HD605-8 30-215


Remarks
47602 Dosing Fuel Pressure_2 kPa psi KDPF

47603 Dosing Fuel Press Sensor Volt_2 V V KDPF
47701 Soot Accumulation_2 g/L g/gal KDPF
47803 Soot Correct. by Ash Influence_2 g/L g/gal KDPF
31200 T/M Input Shaft Speed r/min rpm T/M
31300 T/M Intermediate Shaft Speed r/min rpm T/M
31400 T/M Output Shaft Speed r/min rpm T/M
10007 Radiator Fan Speed Command r/min rpm T/M
10009 Radiator Fan Speed r/min rpm T/M
30100 T/C Oil Temperature ˚C ˚F T/M
30101 T/C Oil Temperature Sens Voltage V V T/M
32500 T/M Oil Temperature ˚C ˚F T/M
32501 T/M Oil Temperature Sensor Volt V V T/M
32600 T/C Oil Pressure MPa psi T/M
32605 T/C Oil Pressure Sensor Voltage V V T/M
07701 Main Flow Selector Valve Press MPa psi T/M
07702 Main Flow Select Press Sens Volt V V T/M
07707 Main Press Variable Valve Press MPa psi T/M
07708 Main Press Variable Sensor Volt V V T/M
31600 ECMV Solenoid Current (High) mA mA T/M
31601 ECMV Solenoid Current (Low) mA mA T/M
31602 ECMV Solenoid Current (1st) mA mA T/M
31603 ECMV Solenoid Current (2nd) mA mA T/M
31604 ECMV Solenoid Current (3rd) mA mA T/M
31605 ECMV Solenoid Current(4thClutch) mA mA T/M
31606 ECMV Solenoid Current (Reverse) mA mA T/M
31609 ECMV Solenoid Current (Lock Up) mA mA T/M
31644 Main Flow Selector Valve Current mA mA T/M
31643 Main Press Variable Sol Current mA mA T/M
41400 Radiator Fan Pump EPC Current mA mA T/M
33704 Brake Command (Rear) % % T/M
36000 Throttle Adjustment Command % % T/M
38900 Clutch Trigger Compensation (L) - - T/M
38901 Clutch Trigger Compensation (H) - - T/M
38902 Clutch Trigger Compensation (1st) - - T/M
38903 Clutch Trigger Compensation (2nd) - - T/M
38904 Clutch Trigger Compensation (3rd) - - T/M
38905 Clutch Trigger Compensation (4th) - - T/M
30-216 HD465-8, HD605-8


Remarks
38906 Clutch Trigger Compensation (R) - - T/M

41800 Clutch Fill Time (Low) msec msec T/M
41801 Clutch Fill Time (High) msec msec T/M
41802 Clutch Fill Time (1st) msec msec T/M
41803 Clutch Fill Time (2nd) msec msec T/M
41804 Clutch Fill Time (3rd) msec msec T/M
41805 Clutch Fill Time (4th) msec msec T/M
41806 Clutch Fill Time (R) msec msec T/M
44201 Throttle Lower Limit Command % % T/M
44200 Throttle Higher Limit Command % % T/M
17302 Dynamic Torque Command % % T/M
38501 Elapsed Time after Gear Shifting sec sec T/M
03208 Source Voltage (T/M Controller) V V T/M
03216 Solenoid Power Voltage (T/M Con) V V T/M
04307 Battery Charge Voltage (T/M Con) V V T/M
With machine
95307 STR/Hoist Oil Pressure MPa psi T/M
lock-out
With machine
95308 STR/Hoist Oil Press S. Volt V V T/M
lock-out
95001 Lockup State ON/OFF ON/OFF T/M
Radiator Fan
ON/OFF ON/OFF
Reverse Sol
Transmission Controller Steering Lockout With machine
03705 ON/OFF ON/OFF T/M
Output 1 Sol. lock-out
STR/Hoist Lockout With machine
ON/OFF ON/OFF
Sol. lock-out
Engine Start Motor
ON/OFF ON/OFF
Relay
Transmission Controller Sol Power Holding
03706 ON/OFF ON/OFF T/M
Output 2 Relay
Machine Lockout With machine
ON/OFF ON/OFF
Lamp lock-out
High Clutch ON/OFF ON/OFF
94100 T/M Initial Learning State 1 T/M
Low Clutch ON/OFF ON/OFF
Reverse Clutch ON/OFF ON/OFF
1st Clutch ON/OFF ON/OFF
94101 T/M Initial Learning State 2 2nd Clutch ON/OFF ON/OFF T/M
3rd Clutch ON/OFF ON/OFF
4th Clutch ON/OFF ON/OFF
31527 Clutch Fill State 1 T/M
HD465-8, HD605-8 30-217


Remarks

31528 Clutch Fill State 2 2nd Clutch ON/OFF ON/OFF T/M
02216 Clutch Fill SW Input 1 T/M
02229 Clutch Fill SW Input 2 2nd Clutch ON/OFF ON/OFF T/M
Shift Lever R ON/OFF ON/OFF
Shift Lever N ON/OFF ON/OFF
Shift Lever D ON/OFF ON/OFF
02211 T/M Controller SW Input 1 T/M
Shift Lever 6 ON/OFF ON/OFF
02212 T/M Controller SW Input 2 Shift Lever 2 ON/OFF ON/OFF T/M
Shift Lever L ON/OFF ON/OFF
Engine Mode
ON/OFF ON/OFF
Selector SW
AISS Low SW ON/OFF ON/OFF
02213 T/M Controller SW Input 3 Machine Lockout T/M With machine
ON/OFF ON/OFF
SW1 lock-out
Machine Lockout With machine
ON/OFF ON/OFF
SW2 lock-out
Starting Motor State ON/OFF ON/OFF
Secondary Travel
02214 T/M Controller SW Input 4 ON/OFF ON/OFF T/M
SW
Secondary S/T State ON/OFF ON/OFF
T/M Oil Filter SW 1 ON/OFF ON/OFF
02215 T/M Controller SW Input 5 T/M
T/M Oil Filter SW 2 ON/OFF ON/OFF
20414 T/M Controller Assembly P/N - - T/M
20413 T/M Controller S/N - - T/M
20201 T/M Controller Program P/N - - T/M
20223 T/M Controller Program Version - - T/M
20224 T/M Controller Data Version - - T/M
30-218 HD465-8, HD605-8


Remarks
35500 Accumulator Oil Pressure Sensor (Front) MPa psi RHC

35506 Accumulator Press Sens Volt (F) V V RHC
35501 Accumulator Oil Pressure Sensor (Rear) MPa psi RHC
35507 Accumulator Press Sens Volt (R) V V RHC
91910 Retarder Pressure (Rear) MPa psi RHC
91912 Retarder Pressure Sens Volt (R) V V RHC
91908 Parking Brake Pressure (Rear) MPa psi RHC
91909 Parking Brake Press Sens Volt(R) V V RHC
91917 Secondary Brake Pressure MPa psi RHC
91918 Secondary Brake Press Sens Volt V V RHC
95302 S/T Pressure MPa psi RHC
95303 S/T Pressure Sensor Voltage V V RHC
07703 Secondary S/T Pressure MPa psi RHC
07705 Secondary S/T Press Sens 1 Volt V V RHC
33900 Retarder Lever Potentio Voltage V V RHC
34304 Hoist Lever Potentio Volt (Main) V V RHC
34305 Hoist Lever Potentio Volt (Sub) V V RHC
34602 Body Positioner Sensor Voltage V V RHC
With automatic
35403 S/T Speed rad/sec rad/sec RHC
suspension
35402 S/T Angle deg deg RHC With KTCS
35400 S/T Angle Potentiometer Voltage V V RHC With KTCS
60201 Acceleration Sensor Voltage V V RHC
32904 Inclination Angle (Lateral) deg deg RHC
32905 Inclination Sens Volt (Lateral) V V RHC
30215 Retarder Oil Temperature (Rear) ˚C ˚F RHC
30212 Retarder Oil Temp Sens Volt (R) V V RHC
49004 KTCS Pressure (Rear Left) MPa psi RHC With KTCS
49005 KTCS Pressure Sensor Volt (R L) V V RHC With KTCS
49006 KTCS Pressure (Rear Right) MPa psi RHC With KTCS
49007 KTCS Pressure Sensor Volt (R R) V V RHC With KTCS
32816 Suspension Pressure (Rear Right) MPa psi RHC
32817 Suspension Press Sens Volt (RR) V V RHC
32814 Suspension Pressure (Rear Left) MPa psi RHC
32815 Suspension Press Sens Volt (RL) V V RHC
37701 ARSC Set SW V V RHC
32701 S/T Oil Temperature ˚C ˚F RHC
32702 Steering Oil Temp. Sensor Volt V V RHC
HD465-8, HD605-8 30-219


Remarks
39704 Wheel Speed (Rear Right) r/min rpm RHC With KTCS
39705 Wheel Speed (Rear Left) r/min rpm RHC With KTCS
45100 Dump Body Seating Command (High) mA mA RHC
45101 Dump Body Seating Command (Low) mA mA RHC
45200 Body Seating Calib Position V V RHC
45300 Cylinder Stopper Calib Position V V RHC
45400 Body Seating Process Time (High) sec sec RHC
45401 Body Seating Process Time (Low) sec sec RHC
33806 Retarder EPC Solenoid Current(R) mA mA RHC
45601 Hoist EPC Solenoid Current mA mA RHC
49008 KTCS EPC Solenoid Current (R L) mA mA RHC With KTCS
49009 KTCS EPC Solenoid Current (R R) mA mA RHC With KTCS
03221 Main Power Voltage (RHC) V V RHC
03222 Solenoid Power Voltage (RHC) V V RHC
04308 Battery Charge Voltage (RHC) V V RHC
Hoist Selector
ON/OFF ON/OFF
Solenoid
Kick out Solenoid ON/OFF ON/OFF
S/T Pump Select
ON/OFF ON/OFF
03709 RHC Output 1 Solenoid RHC
2ndary S/T Motor
ON/OFF ON/OFF
Relay
Parking Interlock
ON/OFF ON/OFF With auto idle stop
Relay
KTCS Shut off
ON/OFF ON/OFF With KTCS
Solenoid
Stop Lamp (Center) ON/OFF ON/OFF
03710 RHC Output 2 Stop Lamp (Right & RHC
ON/OFF ON/OFF
Left)
Brake Cooling Sol
ON/OFF ON/OFF
(R)
Auto Suspension Sol With automatic
ON/OFF ON/OFF
1 suspension
Auto Suspension Sol With automatic
03711 RHC Output 3 ON/OFF ON/OFF RHC
2 suspension
Front Brake Cut off
ON/OFF ON/OFF
Sol
30-220 HD465-8, HD605-8


Remarks
Starting Motor State ON/OFF ON/OFF

Secondary Travel
ON/OFF ON/OFF
SW
02220 RHC Input 1 Parking Brake Sol RHC
ON/OFF ON/OFF
State
Front Brake Cut off
ON/OFF ON/OFF
SW
Retarder Validation
ON/OFF ON/OFF
SW 1
Retarder Validation
02221 RHC Input 2 ON/OFF ON/OFF RHC
SW 2
Service Brake Press
ON/OFF ON/OFF
SW
20265 RHC Assembly P/N - - RHC
20420 RHC S/N - - RHC
20214 RHC Program P/N - - RHC
20231 RHC Program Version - - RHC
20232 RHC Data Version - - RHC
39703 Wheel Speed (FL) r/min rpm ABS With ABS
39702 Wheel Speed (FR) r/min rpm ABS With ABS
43308 ABS Solenoid Current (FL) mA mA ABS With ABS
43309 ABS Solenoid Current (FR) mA mA ABS With ABS
43310 ABS Solenoid Current (RL) mA mA ABS With ABS
43311 ABS Solenoid Current (RR) mA mA ABS With ABS
43312 ABS Pressure (FL) MPa psi ABS With ABS
43313 ABS Pressure Sensor Volt (FL) V V ABS With ABS
43314 ABS Pressure (FR) MPa psi ABS With ABS
43315 ABS Pressure Sensor Volt (FR) V V ABS With ABS
43316 ABS Pressure (RL) MPa psi ABS With ABS
43317 ABS Pressure Sensor Volt (RL) V V ABS With ABS
43318 ABS Pressure (RR) MPa psi ABS With ABS
43319 ABS Pressure Sensor Volt (RR) V V ABS With ABS
43402 ABS Cut V. Pressure MPa psi ABS With ABS
43403 ABS Cut V. Press Sensor Volt V V ABS With ABS
ABS Cut V. (F) ON/OFF ON/OFF ABS With ABS
40960 ABS Con. Output
ABS Cut V. (R) ON/OFF ON/OFF ABS With ABS
ABS Cut Press SW
ON/OFF ON/OFF ABS With ABS
(F)
40937 ABS Con. Input 1
ABS Cut Press SW
(R)
HD465-8, HD605-8 30-221


Remarks
Key Switch C
40939 ABS Con. Input 2 Terminal
Secondary S/T State ON/OFF ON/OFF ABS With ABS
20504 Assembly P/N (ABS Con.) - - ABS With ABS
20505 Serial No. (ABS Con.) - - ABS With ABS
20210 Software P/N (ABS Con.) - - ABS With ABS
20233 Application Version (ABS Con.) - - ABS With ABS
20234 Data Version (ABS Con.) - - ABS With ABS
42602 Exhaust Air Temperature ˚C ˚F KOM PLS
42603 Exhaust Air Temp. Sensor Volt V V KOM PLS
37504 Ambient Air Temperature ˚C ˚F KOM PLS
37505 Ambient Air Temp. Sensor Volt V V KOM PLS
32901 Inclination Angle (Longitudinal) deg deg KOM PLS
32902 Incli Sensor Volt (Longitudinal) V V KOM PLS
SI unit: Metric ton
42200 Payload t t KOM PLS
Non SI unit: Short ton
SI unit: Metric ton
42201 Rated Payload t t KOM PLS Non SI unit: Short
ton
42500 Shift lever N signal ON/OFF ON/OFF KOM PLS
45000 Stop Traveling Flag ON/OFF ON/OFF KOM PLS
34601 Body seating ON/OFF ON/OFF KOM PLS
32803 Suspension Pressure (Front Left) Mpa psi KOM PLS
32809 Suspension Press Sensor Volt(FL) V V KOM PLS
32804 Suspension Pressure(Front Right) Mpa psi KOM PLS
32810 Suspension Press Sensor Volt(FR) V V KOM PLS
32807 Suspension Pressure (Rear Left) Mpa psi KOM PLS
32813 Suspension Press Sens Volt (RL) V V KOM PLS
32806 Suspension Pressure (Rear Right) Mpa psi KOM PLS
32812 Suspension Press Sens Volt (RR) V V KOM PLS
0: Unable to judge
1: Empty and stop
2: Empty and
traveling
42400 Machine State - - KOM PLS 3: Loading
4: Loaded and
traveling
5: Loaded and stop
6: Dumping
03225 Main Power Voltage (K-Plus) V V KOM PLS
30-222 HD465-8, HD605-8


Remarks
K-Plus Startup
ON/OFF ON/OFF
Signal
PLM Lamp Output
ON/OFF ON/OFF
(Red)
03712 KOMTRAX Plus Output KOM PLS
PLM Lamp Output
ON/OFF ON/OFF
(Yellow)
PLM Lamp Output
ON/OFF ON/OFF
(Green)
Auto Transmitting ON/OFF ON/OFF
MMS
KOMTRAXPlus SW Input ON/OFF ON/OFF
02224 Communication KOM PLS
1
External Startup
ON/OFF ON/OFF
Signal
20448 Assembly P/N (KOMTRAXPlus) - - KOM PLS
20449 Serial No. (KOMTRAXPlus) - - KOM PLS
20450 Software P/N (KOMTRAXPlus) - - KOM PLS
20455 Program Version (KOMTRAXPlus) - - KOM PLS
20483 Assembly P/N (MODEM) - - KOM PLS
20484 Serial No. (MODEM) - - KOM PLS
20485 Software P/N (MODEM) - - KOM PLS
20486 Program Version (MODEM) - - KOM PLS
01001 Engine Speed (Tachometer) r/min rpm MON
40000 Travel Speed (Speedometer) km/h MPH MON
30216 Retarder Oil Temperature (Gauge) ˚C ˚F MON
04200 Fuel Level Sensor Voltage V V MON
04201 Fuel Level Sensor Resistance Ω Ω MON
04202 Fuel Level % % MON
55001 A/C Fresh Air Temperature ˚C ˚F MON
03220 Main Power Voltage (Monitor) V V MON
04306 Battery Charge Voltage (Monitor) V V MON
Right Turn Signal ON/OFF ON/OFF
Left Turn Signal ON/OFF ON/OFF
High Beam State ON/OFF ON/OFF
04507 Monitor Input 1 Dimmer SW ON/OFF ON/OFF MON
Lamp SW ON/OFF ON/OFF

Brightness Selector
ON/OFF ON/OFF
SW
Seat Belt SW ON/OFF ON/OFF
Engine Shutdown
04508 Monitor Input 2 ON/OFF ON/OFF MON
2nd SW
Door SW ON/OFF ON/OFF
HD465-8, HD605-8 30-223


Remarks
Key SW ACC ON/OFF ON/OFF

Engine Starter ON/OFF ON/OFF
04509 Monitor Input 3 MON
Preheater State ON/OFF ON/OFF
Unit Selection ON/OFF ON/OFF
Engine Oil Level SW ON/OFF ON/OFF
Coolant Level SW ON/OFF ON/OFF
Air Cleaner SW ON/OFF ON/OFF
04510 Monitor Input 4 MON
With maintenance
S/T Hoist Filter SW ON/OFF ON/OFF
sensor
Retarder Cool Filter With maintenance
ON/OFF ON/OFF
SW sensor
SW 1 ON/OFF ON/OFF
SW 2 ON/OFF ON/OFF
SW 3 ON/OFF ON/OFF
04504 Monitor 1st & 2nd Row SW MON
SW 4 ON/OFF ON/OFF
SW 5 ON/OFF ON/OFF
SW 6 ON/OFF ON/OFF
SW 7 ON/OFF ON/OFF
SW 8 ON/OFF ON/OFF
SW 9 ON/OFF ON/OFF
04505 Monitor 3rd & 4th Row SW MON
SW 10 ON/OFF ON/OFF
SW 11 ON/OFF ON/OFF
SW 12 ON/OFF ON/OFF
SW 13 ON/OFF ON/OFF
04506 Monitor 5th Row SW SW 14 ON/OFF ON/OFF MON
SW 15 ON/OFF ON/OFF
Buzzer ON/OFF ON/OFF
Personal Code Relay ON/OFF ON/OFF
Night SW Lamp ON/OFF ON/OFF
Night Shift Lever
04700 Monitor Output ON/OFF ON/OFF MON
Lamp
Parking Brake SW
ON/OFF ON/OFF
Lamp
Head Lamp (High)
ON/OFF ON/OFF
Relay
00205 Selected Model (Monitor) - - MON
20227 Assembly P/N (Monitor) - - MON
20402 S/N (Monitor) - - MON
20228 Program P/N (Monitor) - - MON
20221 Program Version (Monitor) - - MON
30-224 HD465-8, HD605-8


Remarks
20222 Data Version (Monitor) - - MON

55300 A/C Compressor State ON/OFF ON/OFF MON
55000 A/C Fresh Air Temp Code - - MON
55100 A/C Recirc Air Temp Code - - MON
55200 A/C Control Mode Data (Monitor) - - MON
55201 A/C Control Mode Data (A/C ECU) - - MON
20266 Assembly P/N (Rearview Monitor) - - MON
20421 Program P/N (Rearview Monitor) - - MON
20267 Program P/N (Rearview Monitor) - - MON
20268 Program Version (Rearview Mon) - - MON
*1: Instantaneous fuel consumption (code No: 37300) is a theoretical fuel consumption ratio. (This is a theoretical value and it
slightly differs from the real fuel consumption ratio.)
q Description order of table
This is the displayed order of the "Monitoring Selection Menu" screen.
q Unit
As a display unit, you can select "SI" or "Non SI". (To switch the display unit, perform it on the "Unit Selection" in "Default"
of "Service Menu" screen.
Display unit "mg/st" is the quantity (milligram/stroke) per 1 stroke.
q Relevant component
ENG: The engine controller detects monitoring information.
KDPF: The engine controller detects monitoring information related to KDPF.
T/M: The transmission controller detects monitoring information.
RHC: The retarder and hoist controller detects monitoring information.
ABS: The ABS controller detects monitoring information.
KOM PLS: The KOMTRAX Plus controller detects monitoring information.
MON: The monitor controller detects monitoring information.
HD465-8, HD605-8 30-225

ABNORMALITY RECORD MENU

PROCEDURE TO CERTIFY ABNORMALITY RECORD (MECHANICAL SYSTEMS)
The machine monitor records the failures that occurred in the past and in operation at this time. It classifies them into the me-
chanical system and electrical system abnormality.
To examine "Mechanical Sys Abnormality Record", perform the following procedures.
For the failure code list, see TROUBLESHOOTING, "FAILURE CODES TABLE".
1. Select "Abnormality Record" on "Service Menu" screen.
2. After the "Abnormality Record" screen is shown, use a switch on

the switch panel to select "Mechanical Sys Abnormality Record".
REMARK
Input a code (2-digit) by using the numeral (15) input switch to di-
rectly select the item, and then push ENTER switch (13) to enter
the selection.
30-226 HD465-8, HD605-8

3. After the "Mechanical Sys Abnormality Record" screen is shown,

the following information are shown.
(a): Occurrence sequence of defects from latest to total number
of records
(b): Failure code
(c): Details of failure
(d): Number of occurrences (display range: 0 to 65535 times)
(e): Service meter indication at the initial occurrence
(f): Service meter indication at the last occurrence
RETURN switch (12): Returns to the "Abnormality Record" screen
MENU switch (14): Scrolls the displayed failure to the left again.
REMARK
q If no abnormality is recorded, "There is no abnormality re-
cord." is shown.
q In the mechanical systems abnormality record screen, 50
cases currently stored are shown.
q If the number of occurrence is 1 (first occurrence), the service
meter reading at the first occurrence and that at the last oc-
currence are the same. In addition, when the latest service
meter reading is recovered, the value at the recovery time is
shown, thus the above readings may not be the same.
q If "E" is shown on the left of a failure code, the abnormality is
still occurring or it has not yet been normally restored.
q For all of the failure codes that the machine monitor can re-
cord, see TROUBLESHOOTING, "FAILURE CODES TA-
BLE".
q If the characters in the failure are many, the character strings
display is scrolled.
q The contents of an abnormality record of the mechanical sys-
tem cannot be deleted.
PROCEDURE TO CERTIFY ABNORMALITY RECORD (ELECTRICAL SYSTEMS)
The machine monitor records the failures that occurred in the past and in operation at this time. It classifies them into the me-
chanical system and electrical system abnormality.
To examine "Electrical Sys Abnormality Record", perform the following procedures.
For all of the failure codes that the machine monitor can record, see TROUBLESHOOTING, "FAILURE CODES TABLE".
HD465-8, HD605-8 30-227

Procedure to certify abnormality record

1. Select "Abnormality Record" on "Service Menu" Screen.
2. After the "Abnormality Record" screen is shown, use a switch on

the switch panel to select "Electrical Sys Abnormality Record".
REMARK
the selection.
3. After the "Electrical Sys Abnormality Record" screen is shown,

the following information is shown.
(a): Occurrence sequence of defects from latest to total number
of records
(b): Failure code
(c): Details of failure
(d): Number of occurrences (display range: 0 to 65535 times)
(e): Service meter indication at the initial occurrence
(f): Service meter indication at the last occurrence
RETURN switch (12): Returns to the "Abnormality Record" screen
MENU switch (14): Scrolls the displayed failure to the left again.
30-228 HD465-8, HD605-8

REMARK
q If no abnormality is recorded, "There is no abnormality record." is shown.
q In Electrical system abnormality record, up to 20 of stored records are shown. If the 21st record is stored, the oldest
record will be deleted and the latest 20 records will be shown.
q If the number of occurrence is 1 (first occurrence), the service meter reading at the first occurrence and that at the last
occurrence are the same.
q If "E" is shown on the left of a failure code, the abnormality is still occurring or it has not yet been normally restored.
q For all of the failure codes that the machine monitor can record, see TROUBLESHOOTING, "FAILURE CODES TA-
BLE".
q If the characters in the failure are many, the character strings display is scrolled.
Procedure to delete abnormality record
1. After the "Electrical Sys Abnormality Record" screen is shown,
use a switch on the switch panel to perform the following opera-
tion.
HD465-8, HD605-8 30-229

2. Make sure that the screen becomes the clear mode, then clear
the individual information one by one or all together by using
MENU switch (14).
RETURN switch (12): Returns to the "Abnormality Record"
screen
ENTER switch (13): Validates the deletion of the selected abnor-
mality records
MENU switch (14): Validates the deletion of all abnormality re-
cords
REMARK
The screen is in deleting mode if "CLEAR" is shown on the bot-
tom of the screen.
q To delete a selected abnormality record, use UP switch (10)
or DOWN switch (11) to select the abnormality record, and
then push ENTER switch (13) to execute the deletion of the
abnormality record.
q To clear all abnormality records together, push MENU switch
(14), and then all the records are deleted regardless of the
selection.
q If "E" is shown on the left of a failure code, the clearing oper-
ation is received but the information is not cleared.
3. After the "Electrical Sys. Error Reset" screen is displayed,
operate the switches to clear abnormality records.
RETURN switch (12): Returns to the "Electrical Sys Abnormal-
ity Record" screen (clear mode)
ENTER switch (13): Clears the information
REMARK
q This is the screen shown when a selected abnormality record
to be deleted.
q This is the screen shown when all the abnormality records to

be deleted.
30-230 HD465-8, HD605-8

4. After the screen to notify the completion of the deletion is shown and then "Electrical Sys Abnormality Record" (deleting
mode) screen is shown, the deletion of the selected abnormality record is completed.
REMARK
q This is the screen shown when a selected abnormality record
is deleted.
q This is the shown when all the abnormality records are delet-
ed.
HD465-8, HD605-8 30-231

PROCEDURE TO CONFIRM MAINTENANCE RECORD

The machine monitor records the maintenance information of the filters, oils, which are shown and checked by the following
operations.
If the data are reset in the operator mode when the maintenance is performed, the number of the times of maintenance is re-
corded here.
1. Select "Maintenance Record" on the "Service Menu" screen.
2. When the "Maintenance Record" screen is shown, use a switch

on the switch panel to select the item to be changed.
REMARK
Input a code (2-digit) with the numeral input switch (15) to directly
select the item.
Selectable items from Maintenance Record
Code Item
49 Air Cleaner Cleaning or Change
01 Engine Oil Change
02 Engine Oil Filter Change
41 Fuel Prefilter Change
13 T/M Oil Filter Change
24 T/M Oil and Brake Oil Change
14 Brake System Oil Filter Change
16 Brake Cooling Oil Filter Change
03 Fuel Main Filter Change
30-232 HD465-8, HD605-8

Code Item
04 Hydraulic Oil Filter Change
05 Hydraulic Oil Tank Breather Change
11 Differential Oil Change
50 Final Drive Oil Change
47 KCCV Filter Change
10 Hydraulic Oil Change
48 KDPF Filter Cleaning
52 Fuel Doser Cleaning
Displayed information of "Maintenance Record" screen

(a): Maintenance items
(b): Number of replacements until now
(c): Service meter indication (SMR) at the last replacement
PROCEDURE TO OPERATE MAINTENANCE MODE SETTING

The operating condition of the maintenance function of operator mode can be set and changed using this menu.
q Activates or deactivates the functions of the maintenance items.
q Changes the set up time of change intervals per maintenance items.
q Initializes the set up time for change interval of all the maintenance items.
1. Select "Maintenance Mode Setting" on the "Service Menu"
screen.
HD465-8, HD605-8 30-233

2. When the "Maintenance Mode Setting" screen is shown, use a

switch on the switch panel to select the item to be changed.
REMARK
the selection.
Select items from Maintenance Mode Setting
Code Item
00 Maintenance Mode Change
49 Air Cleaner Cleaning or Change Interval
01 Engine Oil Change Interval
02 Engine Oil Filter Change Interval
41 Fuel Prefilter Change Interval
13 T/M Oil Filter Change Interval
24 T/M Oil and Brake Oil Change Interval
14 Brake System Oil Filter Change Interval
16 Brake Cooling Oil Filter Change Interval
03 Fuel Main Filter Change Interval
04 Hydraulic Oil Filter Change Interval
05 Hydraulic Oil Tank Breather Change Interval
11 Differential Oil Change Interval
50 Final Drive Oil Change Interval
10 Hydraulic Oil Change Interval
99 All Default Value
30-234 HD465-8, HD605-8

3. When the "Maintenance Mode Change" screen is shown, use a

switch on the switch panel to select the item to be changed.
"Maintenance Mode Setting" screen
ENTER switch (13): Validates the selection and the screen
changes to the "Maintenance Mode ON or OFF" screen
4. When the "Maintenance Mode ON or OFF" screen is shown, use

a switch on the switch panel to select the item to be changed.
"ON": All the functions of the maintenance items are activated in
the operator mode.
"OFF": All the functions of the maintenance items are deactivat-
ed in the operator mode.
RETURN switch (12): Cancels the selection and returns the dis-
play to the "Maintenance Mode Change" screen
changes to the "Maintenance Mode Change" screen
REMARK
Once the setting change is confirmed, the changed setting still
has priority, even if the setting of use/not to use per item is set.
HD465-8, HD605-8 30-235

5. When the "Maintenance Notice Time Setting" screen is shown,

use a switch on the switch panel to select the item to be changed.
"Default": A maintenance notice time set in the machine monitor
(manufacturer recommended value, invariable value)
"Set": A maintenance notice time which can be set arbitrarily in
the range between 10 hours and 200 hours. The maintenance
functions in the operator mode operates according to this setting
time (increases or decreases every 10 hours)
UP switch (10): Increases the set value
DOWN switch (11): Decreases the set value
RETURN switch (12): Cancels the setting and returns the display
to the "Maintenance Mode Change" screen
ENTER switch (13): Validates the setting and the screen chang-
es to the "Maintenance Mode Change" screen
REMARK
q The setting is activated by confirming with ENTER switch
(13) and returning to the "Maintenance Mode Setting" screen
with RETURN switch (12).
q When the item set to "ON" is changed 1 hour or more after
the setting start, the machine recognizes it as the reset oper-
ation.
30-236 HD465-8, HD605-8

6. When each maintenance item is selected and the screen is

shown, use a switch on the switch panel to select "ON or OFF
Setting".
changes to the setting screen for each
REMARK
The figure shows an example of when the "Engine Oil Change In-
terval" screen is shown.
7. When the screen to change interval is shown, use a switch on the

switch panel to select "ON" or "OFF".
"ON": Each function of the maintenance items is activated in the
operator mode.
"OFF": Each function of the maintenance items is deactivated in
the operator mode.
RETURN switch (12): Cancels the selection and returns the
screen to the setting screen for each
REMARK
HD465-8, HD605-8 30-237

8. When each maintenance item is selected and the screen is

shown, use a switch on the switch panel to select "Set" and
confirm it.
REMARK
9. When the "Set" screen is shown, use a switch on the switch

panel to select the item to be changed.
"Default": A maintenance setting time set in the machine monitor
(manufacturer recommended value, invariable value)
"Set": A maintenance notice time which can be set arbitrarily. The
maintenance functions in the operator mode operates according
to this setting time (increases or decreases every 25 hours)
UP switch (10): Increases the set value
DOWN switch (11): Decreases the set value
RETURN switch (12): Cancels the setting and returns the screen
to the setting screen for each
ENTER switch (13): Validates the setting and the screen chang-
es to the setting screen for each
REMARK
q The setting is activated by confirming with ENTER switch
(13) and returning to the "Maintenance Mode Setting" screen
with RETURN switch (12).
q When the item set to "ON" is changed 1 hour or more after
the setting start, the machine recognizes it as the reset oper-
ation.
q The figure shows an example of when the "Engine Oil
Change Interval" screen is shown.
NOTICE
A maintenance notice time can be set in "Set" of "Air Cleaner Cleaning or Change Interval". Clean or replace the
air cleaner element when "Air cleaner clogging sensor" of the machine monitor lights up.
30-238 HD465-8, HD605-8

10. When the "All Default Value" screen is shown, use a switch on
the switch panel to select the item to be changed.
When this item is executed, all the setting values of the mainte-
nance item returns to the initial values.
RETURN switch (12): Returns to the "Maintenance Mode Set-
ting" screen
ENTER switch (13): Performs the initialization
When ENTER switch (13) is pushed, "Reset all" is shown. The
initializing is complete when the "Maintenance Mode Setting"
screen is shown.
PROCEDURE FOR OPERATING PHONE NUMBER ENTRY SETTING

The telephone number which is shown together with the "Current Abnormality" in the operator mode can be inputted and
changed according to the following procedure.
The telephone numbers needs to be entered with this function in order to be shown in operator mode.
1. Select "Phone Number Entry" on "Service Menu" screen.
HD465-8, HD605-8 30-239

2. After the "Phone Number Entry" screen is shown, use a switch

on the switch panel to register the phone number or change it.
UP switch (10): Moves the input position to the immediate left
place (if not blank)
DOWN switch (11): Moves the input position to the immediate
right place (if not blank)
ENTER switch (13): Validates the input
MENU switch (14): Clears all the phone numbers inputted
REMARK
q Up to 14 digits can be inputted from the left. Leave the sur-
plus places without inputting any digit.
q If an inputted numeral is wrong, move the cursor (orange
background) to that digit and overwrite it with the correct nu-
meral.
q If you push ENTER switch (13) without inputting a digit, no
phone number is shown in operator mode since there is no
phone number information.
30-240 HD465-8, HD605-8

DEFAULT MENU
PROCEDURE TO SET WITH DEFAULT SETTING MENU (MACHINE MODEL SELECT)
Default menu is used to examine or change default values of the machine monitor and machine.
"Machine Model Selection" function is used to make the controller recognize the current machine model.
1. Select "Default" on "Service Menu" screen.
2. Select "Machine Model Selection" after "Default" screen

appears.
REMARK
Selection procedure is the same as on "Service Menu" screen.
3. While the "Machine Model Selection" screen is shown, use

switches on the switch panel to perform the following operation.
HD465-8, HD605-8 30-241

4. Select the machine model of the machine since selecting the

machine model is enabled.
"Default" screen
REMARK
q Each setting is as shown below after the selection of the ma-
chine model is validated.
"Self-define Monitoring": Clearing the currently stored items.
"Use"/"Not Use" of "Maintenance Mode Setting" and mainte-
nance interval settings are restored to the default value of the
selected model.
"Default (Option Selection)": Default value of the selected
model are restored.
"Energy Saving Guidance": All of the fuel consumption data
are reset.
q Perform the machine model selection first. If the monitor con-
troller is replaced when the machine model has never been
selected, "Machine Model Selection" screen appears after
entering the service menu for the first time. (The screen is dif-
ferent from the one when a machine model has already been
selected.)
5. After the screen which prompts you a key off is shown, turn the
start switch to OFF position.
6. Turn the start switch to ON position after 15 seconds.
See "PROCEDURE TO SET WITH DEFAULT SETTING MENU (OPTION SELECTION)" to perform "Default (Option Selec-
tion)".
PROCEDURE TO SET WITH DEFAULT SETTING MENU (OPTION SELECTION)
"Option Selection" function is used to perform "Machine Model Selection" on the default menu and enable the function when
all the option selection settings are reset or additional options are installed.
30-242 HD465-8, HD605-8

2. Select "Option Selection" after "Default" screen appears.
REMARK
3. When the "Option Selection" screen is shown, check the option

installation state of the machine and set the items.
"Default" screen
REMARK
ENTER switch (13) does not need to be pressed if the setting
change of the selected item is not necessary.
HD465-8, HD605-8 30-243

Setting of optional devices
Item name Default Remarks

Normally, select "F7".
Max. Travel Gear Speed F7
See step 4.
ARAC ADD Normally, select "ADD".
KTCS NO ADD When KTCS is installed, select "ADD".
ABS NO ADD When ABS is installed, select "ADD".
Automatic Suspension NO ADD When an automatic suspension is installed, select "ADD".
Inclination Caution System NO ADD Normally, select "ADD".
Maintenance Sensor NO ADD When the maintenance sensor is installed, select "ADD".
NOTICE
When there is a contradiction between the actual and shown
Tire Size Compensation 0% travel speed, adjust the displayed speed by using this function
(increasing the setting by 1 % increases the travel speed by 1 %
from 0 %).
See step 5.
When auto idle stop is installed, select "ADD". If "NO ADD" is
Auto Idle Stop Timer Setting NO ADD
selected, the auto idle stop function is deactivated.
Machine lock-out NO ADD When machine lock-out is installed, select "ADD".
Be sure to select "ADD". If "NO ADD" is selected, the front brake off
Front brake cut NO ADD
switch is deactivated.
Road Analysis NO ADD When road analysis is installed, select "ADD".
4. Select "Maximum Gear Speed", and select one from "F7", "F6",
"F5", or "F4".
"Option Selection" screen
ENTER switch (13): Validates the selection and the screen re-
turns to the "Option Selection" screen
REMARK
Normally, select "F7".
30-244 HD465-8, HD605-8

5. Select "Tire Size Compensation" for compensation.

UP switch (10): Increases the set value by 1 %
DOWN switch (11): Decreases the set value by 1 %
RETURN switch (12): Cancels the setting operation before vali-
dation and returns the display to “Option Select” screen
ENTER switch (13): Enters the setting and the screen returns to
the "Option Selection" screen
6. When the settings of the items are completed, push RETURN

switch (12) to return to the "Default" screen from the "Option
Selection" screen.
REMARK
If ENTER switch (13) has never been pushed (no change is
made) for setting of any item, this screen will not be shown even
if the display changes from "Option Selection" screen to "Default"
screen.
7. After the screen which prompts you a key off is shown, turn the
start switch to OFF position.
Turning the start switch to OFF position completes "Option Selection" setting.
If it is required to set the start switch to the ON position again, set the start switch to the OFF position, wait for 15 seconds
or more and then set the switch to the ON position.
HD465-8, HD605-8 30-245

PROCEDURE FOR SETTING WITH DEFAULT SETTING MENU (UNIT)

"Unit Selection" function is used to select units of data shown for monitoring.
2. Select "Unit Selection" after "Default" screen appears.
REMARK
3. On the "Unit Selection" screen, select the unit to be set.

"Default" screen
ENTER switch (13): Validates the setting and returns the display
to the "Default" screen
30-246 HD465-8, HD605-8

PROCEDURE TO SET REARVIEW MONITOR SETTINGS WITH DEFAULT SETTING

MENU
The “Rearview Monitor Setting” function is used for the setting required for the removal or installation of the rearview monitor
of camera.
2. Select "Rearview Monitor Setting" after "Default" screen

appears.
REMARK
3. Select "Camera 1 Setting" after "Rearview Monitor Setting"

screen appears.
"Default" screen
HD465-8, HD605-8 30-247

4. Select either "Not Use"/"Use" after "Camera 1 Setting" screen

appears.
"Not Use": Camera is not used
"Use": Camera is used
"Rearview Monitor Setting" screen
ENTER switch (13): Validates the setting and the screen returns
to the "Rearview Monitor Setting" screen
REMARK
q Reverse images (mirror images when it is used for rearview
monitor) are shown.
q Default value at shipment is "Use".
Guide line position adjustment

Readjust the guide line if the position of the rearview camera has changed due to removal or installation of the rearview camera.
REMARK
Perform the following adjustment in order to use "Guide Line Display Mode" (guide line can not be shown). For details of "Guide
Line Display Mode", see "Rearview Monitor Setting" in "Operation and Maintenance Manual".
1. Select "Guide Line Position Setting" after "Rearview Monitor
Setting" screen appears.
REMARK
q Because this adjustment is made with the rearview monitor
constantly, turn OFF "Reverse-interlock Selection mode" be-
fore the adjustment. For "Reverse-interlock Selection" mode,
see the section "REVERSE-INTERLOCK SELECTION
MODE" in "Operation and Maintenance Manual".
q When "Not Use" is selected for "Camera 1 Setting", this item
is not selectable.
30-248 HD465-8, HD605-8

2. After "Guide Line Position Adjustment" screen is shown, adjust the horizontal and vertical positions at each point of the
guide line shown on the rearview monitor according to the following procedure.
1) Select Point 1 from guide line position set.
DOWN switch (11): Moves the selection down by one
item
RETURN switch (12): Cancels the selection and returns
the display to the "Rearview Monitor Setting" screen
ENTER switch (13): Validates the selection and returns
the display to the point positioning adjustment screen
HD465-8, HD605-8 30-249

2) The horizontal position of "Point 1" is adjustable. Move

the position (a) to the tire outside width with the rearview
monitor brightness adjustment switch.
Brightness adjustment switch + (e): Moves the point
rightward
Brightness adjustment switch - (f): Moves the point left-
ward
3) Push ENTER switch (13) and fix the indicated position.
30-250 HD465-8, HD605-8

4) The vertical position of "Point 1" is adjustable. Move the

position (b) to the end of the dump body with the rearview
monitor brightness adjustment switch.
Brightness adjustment switch + (e): Moves the point
upward
Brightness adjustment switch - (f): Moves the point down-
ward
5) Push ENTER switch (13) and fix the indicated position.
6) The display returns to point selection screen. On this

screen, adjust the guide line positions at points 2 to 4
according to the same procedure.
HD465-8, HD605-8 30-251

7) Make sure that the images on the rearview monitor are

normal as shown in the figure, and that the machine width
guide line (g) is aligned with the tire outside width (c) and
the distance guide line (h) is aligned with the line of dump
body rear end (d).
(g): Width guide line (green)
(h): Distance guide line (red)
REMARK
If "Reverse-interlock Selection mode" is turned off in the
procedure 1), turn it on.
The guide line position adjustment is completed.
Procedure to initialize Rearview monitor

Whenever you have replaced the rearview monitor, be sure to initialize the rearview monitor with this function.
1. Select "Rearview Monitor Initialization" after "Rearview Monitor
Setting" screen appears.
30-252 HD465-8, HD605-8

2. Start the initialization after "Guide Line Position Setting" screen

appears.
RETURN switch (12): Returns to the "Rearview Monitor Setting"
screen
ENTER switch (13): Performs the initialization
REMARK
Push ENTER switch (13) to perform the initialization. "Rearview
Monitor Setting" returns to the default values.
"Guide Line Display Mode": OFF (Hides the reference line)
"Reverse-interlock Selection mode": ON
"Camera 1 Setting": Use
"Guide Line Position Setting": Not set
The initialization is completed if the "Initialization completed." screen

appears after pressing ENTER switch (13) and then "Rearview Mon-
itor Setting" screen appears.
PROCEDURE TO SET KOMTRAX Plus SETTING WITH THE DEFAULT SETTINGS MENU
Disconnection detection of LAN cable connected to KOMTRAX Plus controller can be set up on "KOMTRAX Plus Setting".
Change the setting when KOMTRAX Plus controller is replaced, or download method which can be done outside the operator's
cab is changed from wireless LAN to LAN cable (downloading on the ground level specification).
REMARK
The setting also needs to be changed if the download method has been modified from downloading on the ground level to
wireless LAN.
HD465-8, HD605-8 30-253

2. Select "KOMTRAX Plus Setting" after "Default" screen appears.
REMARK
3. Select the LAN port to be set on the "KOMTRAX Plus Setting"

screen.
"Default" screen
4. Select the detection setting of each LAN port when "Abnormality

Detection" screen of the selected LAN port appears on the
monitor.
"Default" screen
REMARK
For the setting of the detection, see "Data download method and
the setting of failure detection system".
30-254 HD465-8, HD605-8

Data download procedure and the setting of failure detection system
Download method which can be done outside the

LAN port Setting of failure detection
operator's cab
1 No detection
Via Wireless LAN
2 Enable detection
Through LAN cable (ground level download specification) 1 No detection

(*1) 2 No detection
*1: Use the connector for downloading on the ground level for the downloading.
5. Push RETURN switch (12) after setting the LAN ports.
"KOMTRAX Plus setting is changed Please turn the key off. Set-
tings will be valid after turning the key on next time." appears on
the screen, and turn the start switch to OFF position.
When the start switch is turned to ON position again, the setting is valid.
PROCEDURE TO SET AUTO-IDLE STOP TIMER SETTING WITH THE DEFAULT SETTING
MENU
"Auto Idle Stop Timer Fixing" function is used to set the time selectable on auto idle stop time setting in the operator mode.
REMARK
This item is shown only when "Auto Idle Stop Timer Fixing" is set to "ADD".
HD465-8, HD605-8 30-255

2. Select "Auto Idle Stop Timer Fixing" after "Default" screen

appears.
REMARK
3. Select the time after "Auto Idle Stop Timer Fixing" screen
appears.
Flexible: Selection from OFF to 60 minutes is available.
OFF: Auto Idle Stop function is not used.
x-minute fixing: OFF, or longer time than the selected time is not
available.
"Default" screen
REMARK
q When this setting is "OFF", Auto Idle Stop does not operate.
Auto Idle Stop Time Setting in the operator mode is disabled.
q The maximum value of the auto idle stop time must be set af-
ter checking compliance with the applicable law, which differs
by region.
30-256 HD465-8, HD605-8

DIAGNOSTIC TESTS
PROCEDURE TO OPERATE CYLINDER CUT-OUT OPERATION TESTS
Testing menu is used to check the machine or reset the settings of the machine monitor.
Cylinder cutout mode operation means to run the engine with one or more fuel injectors disabled electrically to reduce the num-
ber of effective cylinders. This operation is used to identify a cylinder that does not output power normally (combustion in it is
abnormal).
1. Select "Diagnostic Tests" on "Service Menu" screen.
2. After the "Diagnostic Tests" screen is shown, use a switch on the

switch panel to select "Cylinder Cutout Mode Operation".
REMARK
3. After the "Cylinder Cutout Mode Operation" screen is shown, use

a switch on the switch panel to select a cylinder to be cut out.
UP switch (10): Moves the selection to the left by one item
DOWN switch (11): Moves the selection to the right by one item
RETURN switch (12): Returns to the "Diagnostic Tests" screen
REMARK
q This operation can be performed while the engine is running.
q If background (a) of the selected cylinder number becomes
white after you push ENTER switch (13), the cylinder is cut
out.
q If the machine monitor cuts out a cylinder but the engine con-
troller cannot cutout that cylinder, the background (a) of the
cylinder number becomes yellow.
q One or more cylinders can be cutout.
HD465-8, HD605-8 30-257

q Holding displayed data

If you push MENU switch (14) during the cylinder cutout op-
eration, the shown information is held view (b). (Real-time in-
formation is kept shown on the left side).
If you push MENU switch (14) while the data is held, the data
holding function is canceled.
The holding function is available for a cylinder, regardless of
whether it is cutout or not.
If a normally operating cylinder is cut out, the following phenom-
ena occur. If the engine is running at near high idle, however, the
engine speed may not lower for the reason of engine control. In this case, adjust the accelerator pedal stroke to lower the
engine speed and judge by increase of the injection rate command.
q Decrease in engine speed
q Fuel Inject Command (quantity) increases.
4. When you change a cylinder to be cutout or when cylinder cutout operation is finished, use a switch on the switch panel to
select a cutout cylinder to be reset.
REMARK
q Select a cutout cylinder to reset the same way as you select a cylinder to be cut out.
q This operation can be performed while the engine is running.
q If background (a) of the selected cylinder number changes to gray when you push ENTER switch (13), the cylinder is
released the cutout.
q If the machine monitor releases a cutout cylinder but the engine controller cannot release the cutout cylinder, the back-
ground (a) of the cylinder number becomes red.
q The cutout cylinder mode operation is not automatically released after the screen returns to the operator mode. Accord-
ingly, be sure to perform the releasing operation after the cylinder cutout mode operation is finished.
PROCEDURE TO OPERATE REGENERATION FOR SERVICE TEST MENU
Active regeneration for service means to the method of burning soot by performing aftertreatment devices regeneration, re-
gardless of the soot accumulation.
2. When the "Diagnostic Tests" screen is shown, use a switch on

the switch panel to select "Active Regeneration for Service".
REMARK
q Selection procedure is the same as on "Service Menu"
screen.
q While the Aftertreatment Devices Regeneration status is in
Manual Stationary Regeneration or stopped, "Active Regen-
eration for Service" cannot be selected.
30-258 HD465-8, HD605-8

3. When the "Active Regeneration for Service" screen is shown, the

following information are shown corresponding to the Aftertreat-
ment Devices Regeneration condition. Set the Aftertreatment
Devices Regeneration according to the given messages.
a: Soot accumulation level
b: Aftertreatment devices regeneration status
c: Selectable items
d: Message
1) Select "Manual Stationary Regeneration" on "Active

Regeneration for Service" screen.
RETURN switch (12): Returns to the "Diagnostic Tests"
screen
ENTER switch (13): Executes the manual stationary
regeneration.
REMARK
q The screen changes to the "Monitoring Selection
Menu" screen which enables monitoring of machine
information during active regeneration by performing
the following switch operation during the active re-
generation for service.
q Switch operation: While you push Down switch (11),
push down in sequence (1), (2), and (3) of numeral in-
put switches.
To return to "Active Regeneration for Service" screen
from "Self-define Monitoring" screen, push RETURN
switch (12).
q For the monitoring operation, see "PROCEDURE TO EXAMINE SELF-DEFINE MONITOR INFORMATION" of
"SET AND OPERATE OF MACHINE MONITOR".
q "Active Regeneration for Service" can be executed under the following state:
Accelerator pedal: Not depressed (OFF)
Gear shift lever: NEUTRAL position (N)
Parking brake switch: (P) position
HD465-8, HD605-8 30-259

q Before performing "Manual Stationary Regeneration", make sure the surrounding environment is safe, no peo-
ple and no combustibles are in the area. When you have to move the machine again for the sake of security,
move it to a safe place and repeat the operation from the start.
q "Active Regeneration for Service" stops automatically after 40 minutes. However, if the regeneration has been
started after the soot accumulation reaches 4 g/l and above, regeneration continues until the soot accumulation
decreases to 0.99 g/l and below. In this case, it may continue over 40 minutes.
2) After the active regeneration for service is complete,
"Regeneration completed." is shown on the screen.
REMARK
If ENTER switch (13) is pushed during the manual sta-
tionary regeneration, "Stop manual stationary regenera-
tion?" is shown on the screen. You can stop the
regeneration by pushing ENTER switch (13) again.
RETURN switch (12): Does not stop regeneration (man-
ual stationary regeneration is continued)
ENTER switch (13): Stops regeneration
PROCEDURE TO OPERATE THE TEST MENU (KDPF MEMORY RESET)

"KDPF Memory Reset" resets KDPF information saved in the machine. Refer to this section and reset KDPF information after
cleaning or replacing KDOC, cleaning or replacing KCSF, and cleaning or replacing the fuel doser.
30-260 HD465-8, HD605-8

2. Select "KDPF Memory Reset" with the switches after "Diagnostic

Tests" screen appears.
REMARK
3. On the "KDPF Memory Reset" screen, select an item to be reset.

HD465-8, HD605-8 30-261

If the KDPF memory in any components needs to be reset, see

"The list of components and its KDPF memory need to be reset".
REMARK
Perform the applicable operation. For details, see TROUBLE-
SHOOTING, "PRECAUTIONS FOR CLEANING AND REPLAC-
ING KDPF (KCSF and KDOC)".
30-262 HD465-8, HD605-8

The list of components and its KDPF memory need to be reset
Components Performance criteria Items

KCSF-A (1) Clean or replace KDPF Change and KDPF Cleaning
KDOC-A (2) Clean or replace KDOC Change
Fuel doser-A (5) Clean or replace Fuel Doser Cleaning
KCSF-B (3) Clean or replace KDPF Change_2 and KDPF Cleaning_2
KDOC-B (4) Clean or replace KDOC Change_2
Fuel doser-B (6) Clean or replace Fuel Doser Cleaning_2
4. After "Do you want to reset?" is shown, confirm the operation with
the switch panel.
RETURN switch (12): Returns to the previous screen
ENTER switch (13): Resets the setting
When the memory has been reset successfully, "Reset complet-
ed." appears on the screen. If an error occurs while resetting the
memory, "Reset failed." appears on the screen.
OPERATE ENGINE CONTROLLER ACTIVE FAULT CLEAR TEST MENU

The engine controller detects the occurred in-range error. Failure codes related to occurred error can be cleared on the ma-
chine monitor.
HD465-8, HD605-8 30-263

2. Select "Engine Controller Active Fault Clear" with the switches

after "Diagnostic Tests" screen appears.
REMARK
3. When the "Engine Controller Active Fault Clear" screen is

shown, select the engine controller with switches.
q When clearing the in-range error codes starting with CA: Se-
lect "Engine Controller".
q When clearing the in-range error codes starting with CB: Se-
lect "Engine Controller_2".
4. After "Reset?" is shown, confirm the operation with the switch

panel.
ENTER switch (13): Clears the failure code
"Reset!" appears when the failure code is cleared.
30-264 HD465-8, HD605-8

PROCEDURE TO OPERATE ASH IN SOOT ACCUMULATION CORRECTION TEST MENU

To perform the correction for the ash accumulation quantity in the soot accumulation, refer to this section.
1. Perform "KDPF Cleaning", and then perform "KDPF Change". See "PROCEDURE TO OPERATE THE TEST MENU
(KDPF MEMORY RESET)".
3. Make sure that the system operation lamp is off, and turn the start switch to ON position.
5. Select "Ash in Soot Accumulation Correction" with the switches

after "Diagnostic Tests" screen appears.
REMARK
REMARK
Keep the engine running at low idle without depressing the accel-
erator pedal.
7. Make sure that the status value "0" of "Test State" and "Test
State_2" is flashing.
UP switch (10): Starts correction
MENU switch (14): Switches to other screen
When "0" is flashing, you can perform the correction.
HD465-8, HD605-8 30-265

REMARK
q Previous screen shows the condition of the KDPF-A (1) on
the right side of the machine.
q The current screen ("_2" is in the name of testing menu)
shows the condition of the KDPF-B (2) on the left side of the
machine.
q For the display of "Test State", refer to the following sections
"Categorization of test state" and "Parameter list of test state".
8. Start the correction by pressing UP switch (10).

DOWN switch (11): Stops correction
REMARK
q When the status value "10" of "Test State" and "Test State_2"
starts flashing, "Ash in Soot Accumulation Correction" will
start.
q "Ash in Soot Accumulation Correction" is completed in ap-
proximately 2 hours.
q Push MENU switch (14) to change the screens and displays
the correction status of KDPF-A (1) on "Ash in Soot Accumu-
lation Correction" screen, and KDPF-B (2) on "Ash in Soot
Accumulation Correction_2" screen.
30-266 HD465-8, HD605-8

9. When "20" of "Test State" and "Test State_2" flash, check the
test result by pressing MENU switch (14).
10. After you confirm the result, turn the start switch to OFF position.
REMARK
The correction value is written in the engine controller about 1
minutes after turning the start switch to OFF position.
Categorization of test state
Test State (a), (b) Content

0 Waiting operation for test (State of the test can be started by pressing test start switch)
Under
normal 10 Test in operation
condition
20 The test is complete normally
Under abnormal
30 to 41 The test cannot be operated or continued
condition
(a): Test State

(b): Test State_2
REMARK
q "Test State" means the state of KDPF-A.
q "Test State_2" means the state of KDPF-B.
Parameter list of test state
Test
Content Detail Required action
State
Waiting for starting The machine monitor stops aftertreatment
0 Start the test by pressing the test start switch.
(Initial status) devices regeneration
Operating "Ash in Soot Accumulation
10 Test in operation Wait for the test to finish.
Correction"
HD465-8, HD605-8 30-267

Test
Content Detail Required action
State
q If "Please turn the key off" is shown, set the
start switch to OFF and shut down the en-
gine controller. (*1)
q If "STOP" is shown, push the relevant
20 Test is complete Test is complete
switch to return the machine to the initial
status.
Other than the above, the machine returns to
the initial status automatically.
The machine status The machine's safety status is not q Set the parking brake switch to (P) position.
30
is not safe established q Do not depress the accelerator pedal.
31 Lowering fuel level Caution for lowering fuel level is shown Fill the fuel.
Test is unavailable The error prohibiting aftertreatment devices Refer to "TROUBLESHOOTING" to perform
32
(1) regeneration is shown the diagnosis for the failure code displayed.
Within 20 seconds
Wait 20 seconds or more after the engine
33 after the engine Within 20 seconds after the engine starts
starts and restart the test.
starts
Engine is stopped Start the engine and restart the test.
Test is unavailable
34 Refer to "TROUBLESHOOTING" to perform
(2) A specific error is displayed
the diagnosis for the failure code displayed.
Test is unavailable
35 The accelerate pedal is depressed Reduce the engine speed and restart the test.
(3)
Test is unavailable Refer to "TROUBLESHOOTING" to perform
36 A specific error is displayed
(4) the diagnosis for the failure code displayed.
q The engine operation status is not sta-
Test is unavailable Restart the test with the engine running at low
37 ble
(5) idle.
q Immediately after the engine is started
Test is unavailable Refer to "TROUBLESHOOTING" to perform
39 A specific error is displayed
(6) the diagnosis for the failure code displayed.
Governor status of
Restart the test with the engine running at low
40 engine control is not The engine control status is not stable
idle.
matched
Test is unavailable Overheating or oil pressure low abnormal Refer to "TROUBLESHOOTING" to perform
41
(7) error is displayed the diagnosis for the failure code displayed.
*1: The shutdown of engine controller is complete when the system operation lamp is turned off 1 minute after the start switch
is set to OFF.
30-268 HD465-8, HD605-8

ADJUSTMENT MENU
PROCEDURE TO ADJUST ECMV AUTOMATIC COMPENSATION WITH ADJUSTMENT
MENU
Adjustment menu is used to check the various settings of the machine or to adjust the value.
"ECMV Automatic Compensation" function corrects the differences in operational feeling due to the individual character of
ECMV to a certain level through the transmission controller.
The adjustment operation is performed automatically 4 times for each High, Low, 1st, 2nd, 3rd, 4th, and Reverse.
q Transmission oil temperature: 70 to 80 °C
q Parking brake switch: (P) position
q AISS LOW switch: ON (Low)
q Gear shift lever: N position
NOTICE
3. To switch to the "Service Menu" screen from the standard

screen, use a switch on the monitor panel to perform the
following operation.
HD465-8, HD605-8 30-269

4. Select and display "Pre-defined Monitoring" (01/28).

REMARK
in operation.
6. Shift the gear shift lever to D position with the brake pedal
correctly depressed with your left foot. And make sure that "F2"
7. Stall the torque converter with the accelerator pedal gradually to
raise the transmission oil temperature to between 70 to 80 °C.
k Keep the brake pedal depress fully.
NOTICE
Be careful of the increase in the torque converter oil temper-
ature during a stall test. Do not allow the torque converter to
become too hot.
8. Return the gear shift lever to the N position and hold it for 3 minutes and make sure that the transmission oil temperature
is stable between 60 and 70 ˚C.
9. Return to the "Service Menu" screen, select "Adjustment".
standard screen
30-270 HD465-8, HD605-8

10. When the "Adjustment" screen is shown, use a switch on the

switch panel to select "ECMV Automatic Compensation".
11. Push ENTER switch (13) to start adjustment after START is

shown in (a).
RETURN switch (12): Returns the display to the "Adjustment"
screen without adjusting the setting.
ENTER switch (13): Starts adjustment
of a monitored value (If the Hold is selected, "HOLD" part is
hatched).
When "ECMV Automatic Compensation" is started, the adjust-

ment is performed 4 times for each ECMV automatically and con-
tinuously.
REMARK
q "---" is shown in (c) during adjustment.
q The adjustment order of ECMV and the display of machine
monitor (b) are as follows.
HD465-8, HD605-8 30-271

The adjustment order of ECMV and the display of machine monitor
Adjustment Display of Machine Monitor (b)

ECMV
order 1st Time 2nd Time 3rd Time 4th Time
1 High H-1 H-2 H-3 H-4
2 Low L-1 L-2 L-3 L-4
3 1st 1-1 1-2 1-3 1-4
4 2nd 2-1 2-2 2-3 2-4
5 3rd 3-1 3-2 3-3 3-4
6 Reverse R-1 R-2 R-3 R-4
7 4th 4-1 4-2 4-3 4-4
12. The result "OK" (normal) or "NG" (abnormal) is shown for each adjustment operation. Perform the procedures according
to the results.
q The display when adjustment is finished normally
When "4-4" (last ECMV) is shown in (b) and "0" (OK) in (c),
all ECMV is normal.
q When "0:OK" is shown:
The adjustment operation is finished normally. Per-
form step 13.
REMARK
(b): Adjusted ECMV
(c): Adjustment result
q The display when adjustment is finished abnormally

When other than "0" (OK) is shown in (c), ECMV has an ab-
normality or it is out of adjustment condition. ECMV with an
abnormality is shown in (b).
The status and measures shown in (c) are as follows.
q When "1: NG (Out of Condition)" is shown:
Make sure the transmission oil temperature and the
conditions at adjustment again and repeat the proce-
dures from step 10.
q When "2: NG (No Fill Signal)" is shown:
Make sure that it is normal, perform the failure diagnosis for failure codes [15S*MA] and [DDT*KA] and repeat
the procedures from step 10. (Symbols with * mark differ according to the target clutch.)
q When "3: NG (Over Compensation)" is shown:
Make sure that it is normal, perform the failure diagnosis for failure code [15S*L1] and repeat the procedures
from step 10. (Symbols with * mark differ according to the target clutch.)
13. When the adjustment operation is finished normally, turn the start switch to OFF position.
REMARK
q The adjustment value is recorded in the transmission controller about 3 seconds after the start switch is set to the OFF
position.
q If it is required to set the start switch to the ON position immediately after adjustment, set the start switch to the OFF
position, wait for 10 seconds or more and then set the switch to the ON position.
30-272 HD465-8, HD605-8

PROCEDURE TO ADJUST T/M INITIAL LEARNING WITH ADJUSTMENT MENU

k To perform the learning operation, be sure to secure the wider travel area, and drive the machine with extreme care
for the safety of the surroundings.
"T/M Initial Learning" function is used to self-adjust wearing change of the transmission clutch via the transmission controller
and keep certain gear change feeling.
Transmission oil temperature: 70 to 80 °C
1. See "PROCEDURE TO ADJUST ECMV AUTOMATIC COMPENSATION WITH ADJUSTMENT MENU" to correct the
differences in operational feeling of each ECMV.
2. See "PROCEDURE TO ADJUST T/M INITIAL LEARNING
RESET WITH ADJUSTMENT MENU" to check the initialization
state of the initial learning data of transmission (a).
"Adjustment" screen
q When "0: Learning Completed" is shown, see "PROCEDURE
TO ADJUST T/M INITIAL LEARNING RESET WITH AD-
JUSTMENT MENU" to perform "T/M Initial Learning Reset".
REMARK
If the gear shift lever is in other than N position, "2: Out of
Reset Condition" is shown and the reset is unavailable.
q When "1: Learning Not Done Yet" is shown, push RETURN
switch (12) to proceed to step 3.
3. Return to the "Adjustment" screen, select "T/M Initial Learning".

HD465-8, HD605-8 30-273

4. When the "T/M Initial Learning" screen is shown, check if the

transmission oil temperature is within the condition.
RETURN switch (12): Returns to the "Adjustment" screen
of a monitored value (If the Hold is selected, "HOLD" part is
hatched).
NOTICE
When the adjustment is performed out of the condition
range, time lag or gear shift shock may occur.
REMARK
For details on how to increase the transmission temperature, see
"PROCEDURE TO ADJUST ECMV AUTOMATIC COMPENSA-
TION WITH ADJUSTMENT MENU".
5. Set the AISS LOW switch to ON (Low) position.

6. Start the engine and operate the gear shift lever as follows with
the accelerator pedal not depressed (low idle).
kWhen the gear shift lever is set to R position, the machine
moves backward. Drive the machine with extreme care for the
safety of the surroundings.
Gear shift lever operation: N→R→N
7. When the "T/M Initial Learning" is shown, check the learning

state of "Reverse Clutch".
q When the display of "T/M Initial Learning" is "ON", proceed to
next step.
q When the display of "T/M Initial Learning" is "OFF", repeat
steps 6 to 7 for it to be "OK".
REMARK
"ON" or "OFF" can be used for states other than "Reverse
Clutch".
8. Set the gear shift lever to the F6 position and depress the accel-
erator pedal to shift up from F1 to F6.
Upshift: F1→F2→F3→F4→F5→F6
9. After you operate for 10 seconds in F6, release the accelerator
pedal, and shift down to F1.
Downshift: F6→F5→F4→F3→F2→F1
NOTICE
Do not depress the brake pedal in coasting.
30-274 HD465-8, HD605-8

10. Stop the machine and check the learning state of "4th Clutch" in
the "T/M Initial Learning" screen.
next step.
REMARK
Clutch" or "4th Clutch".
11. Check again that the learning states of "Reverse Clutch" and "4th
Clutch" are "ON".
REMARK
Clutch" or "4th Clutch".
erator pedal to shift up to F4.
Upshift: F1→F2→F3→F4
13. After you operate for 10 seconds in F4, release the accelerator
pedal, and shift down to F1.
Downshift: F4→F3→F2→F1
NOTICE
HD465-8, HD605-8 30-275

14. Stop the machine and check the learning state of "2nd Clutch" in
next step.
REMARK
Clutch", "2nd Clutch", or "4th Clutch".
15. Check again that the learning states of "Reverse Clutch", "2nd
Clutch", and "4th Clutch" are "ON".
REMARK
Clutch", "2nd Clutch", or "4th Clutch".
16. Set the gear shift lever to the F5 position and depress the accelerator pedal to shift up to F5.
Upshift: F1→F2→F3→F4→F5
17. After you operate for 10 seconds in F5, release the accelerator pedal, and shift down to F1.
Downshift: F5→F4→F3→F2→F1
NOTICE
30-276 HD465-8, HD605-8

18. Stop the machine and check the learning state of "High Clutch"
in the "T/M Initial Learning" screen.
next step.
REMARK
"ON" or "OFF" can be used for states other than "High Clutch",
"Reverse Clutch", "2nd Clutch", or "4th Clutch".
19. Check again that the learning states of "High Clutch", "Reverse
Clutch", "2nd Clutch", and "4th Clutch" are "ON".
REMARK
"ON" or "OFF" can be used for states other than "High Clutch",
"Reverse Clutch", "2nd Clutch", or "4th Clutch".
erator pedal to shift up to F3.
Upshift: F1→F2→F3
NOTICE
q Be careful not to shift up to F4.
q If it is shifted up to F4, do it again by starting from F1.
21. After you operate for 10 seconds in F3, depress the accelerator
pedal to travel end and shift to "F4".
Upshift: F3→F4
HD465-8, HD605-8 30-277

22. Stop the machine and check the learning state of "Low Clutch"
and "3rd Clutch" in the "T/M Initial Learning" screen.
next step.
REMARK
"ON" or "OFF" can be used for the state of "1st Clutch".
23. Check again that the learning states are "ON" other than "1st
Clutch".
REMARK
"ON" or "OFF" can be used for the state of "1st Clutch".
24. Set the gear shift lever to the F2 position and depress the accelerator pedal to shift up to F2.
Upshift: F1→F2
25. After you operate for 10 seconds in F2, release the accelerator pedal, and shift down to F1.
Downshift: F2→F1
NOTICE
30-278 HD465-8, HD605-8

26. Stop the machine and check the learning state of "1st Clutch" in
next step.
27. Make sure that all learning states are "ON".
When all learning states are "OK", the initial learning is finished correctly.
When "T/M Initial Learning" is finished correctly, push RETURN
switch (12) several times to return to the standard screen and then
set the start switch to the ON position.
HD465-8, HD605-8 30-279

PROCEDURE TO ADJUST T/M INITIAL LEARNING RESET WITH ADJUSTMENT MENU

"T/M Initial Learning Reset" function is used to initialize the initial learning data of the transmission via the transmission con-
troller. Perform it if necessary when doing the transmission initial learning.
1. Select "Adjustment" on "Service Menu" screen.

switch panel to select "T/M Initial Learning Reset".
30-280 HD465-8, HD605-8

3. After the "T/M Initial Learning Reset" screen is shown, check

initialization condition (a).
q When "0: Learning Completed" is shown, push ENTER
REMARK
If the gear shift lever is in other than N position, "1: Out of Re-
set Condition" is shown and the reset is unavailable.
q When "1: Learning Completed" is shown, push RETURN
4. When the "Adjustment Value Check" screen is shown, push

ENTER switch (13) again to reset.
HD465-8, HD605-8 30-281

5. After performing the reset, check that the initialization state (a) is
"1: Learning Not Done Yet", and push the RETURN switch (12).
The initial learning data of transmission has been initialized. Perform "T/M Initial Learning" of the adjustment menu.
30-282 HD465-8, HD605-8

PROCEDURE TO ADJUST (ENGINE MODE FIXING)

"Engine Mode Fixing" function is used to fix the engine output to a specific torque curve when checking the engine output via
the transmission controller.
This is used to check while the engine mode is being fixed.
2. When the "Adjustment" screen is shown, select "Engine Mode

Fixing".
HD465-8, HD605-8 30-283

3. When the "Engine Mode Fixing" screen is shown, push the

numeral input switch (15) to display the "Numeric Input" screen.
REMARK
q Pushing any one of 0 to 9 numeral input switch displays the
"Numeric Input" screen.
q If the parking brake is not working, "5" of "Out of Condition"
is shown and the setting of engine mode fixing is not avail-
able.
4. When the "Numeric Input" screen is shown, enter the number

corresponding to the engine output mode, and push ENTER
switch (13).
"Engine Mode Fixing" includes the following:
0: "Normal" state where the engine output curve is not fixed (gear
speed is not fixed)
1: "Power" state where the gear speed is N (neutral) or the en-
gine torque curve is set with lockup
2: "Traction Restriction" state where the gear speed is N (neutral)
or the engine torque curve is set without lockup
3: "E H-Load" is shown but no need to select
4: "E L-Load" is shown but no need to select
UP switch (10): Not used
DOWN switch (11): Not used
RETURN switch (12): Cancels the input
MENU switch (14): Clears all the input values
Numerical input switch (15): Enters a numeric
30-284 HD465-8, HD605-8

5. Push ENTER switch (13) again.
The change is confirmed, and the engine mode corresponding to

the selected condition is fixed.
REMARK
q When the engine mode is fixed, the gear speed varies de-
pending on the gear shift lever position according to "Gear
shift lever position and gear speed list".
q When the engine mode is fixed (item other than "0" is select-
ed), the maximum speed of the radiator fan speed is con-
trolled.
q If RETURN switch (12) is pressed to return to the "Adjust-
ment" screen while engine mode is being fixed, the selected
engine output mode is canceled, and the engine mode re-
turns to "Normal".
HD465-8, HD605-8 30-285

Gear shift lever position and gear speed list
Gear shift lever position Gear speed

R N
N N
D F2
6 F2
5 F2
4 F2
3 F2
2 F2
L F2
PROCEDURE TO ADJUST (FAN MODE FIXING)

"Fan Mode Fixing" function allows you to fix the ratio of the radiator fan speed to the engine speed to any level through the
transmission controller.
This is used to check the radiator fan speed.
2. When the "Adjustment" screen is shown, select "Fan Mode

Fixing".
30-286 HD465-8, HD605-8

3. When the "Fan Mode Fixing" screen is shown, push the numeral
input switch (15) to display the "Numeric Input" screen.
REMARK
Pushing any one of 0 to 9 numeral input switch displays the "Nu-
meric Input" screen.
4. When the "Numeric Input" screen is shown, use the numeric

input switch (15) to select a fan mode number (0 to 3) for which
you want to fix and push ENTER switch (13).
"Fan Mode Fixing" includes the following:
"0: Normal"
"1: Brake" (Sets the maximum mechanical speed used when the
brake is operated)
"2: Max" (Sets the maximum regulatory speed used in the normal
operation)
"3: Min" (Sets the minimum regulatory speed used in the normal
operation)
REMARK
UP switch (10) and DOWN switch (11) functions, but these are
not used in this adjustment. When the switch has been pressed,
push MENU switch (14) to delete display, and then input numeric
value again.
HD465-8, HD605-8 30-287

5. The "Fan Mode Fixing" screen is shown again and the user is
asked to validate the change. Push ENTER switch (13) to vali-
date the change.
(a): Current setting
(b): Setting to be changed
When the change is validated, the validated value is shown in (a).
REMARK
The set content is held even after returning to "Adjustment"
screen by pressing RETURN switch (12), until the start switch is
turned to OFF position.
As the selected fan mode is fixed, check the engine speed and
radiator fan speed from "Self-define Monitoring" on "Service
Menu".

“Steering Pump Displacement Fixing” function is used to fix the swash plate of the steering pump at the maximum through the
retarder/hoist controller. This is used to check the hydraulic pressure of the steering circuit.
Dump body: Seated
1. Make sure that the dump body is seated.
30-288 HD465-8, HD605-8

3. When the "Adjustment" screen is shown, select "S/T Pump

Swash Plate Fixing".
"Adjustment" screen
4. When the "S/T Pump Swash Plate Fixing" screen is shown, fix
the steering pump swash plate at the maximum.
"0: Normal"
"1: Max" (Sets the maximum regulatory speed)
(b): Behavior when ENTER switch (13) is pressed
RETURN switch (12): Cancels the setting and returns to the "Ad-
justment" screen
ENTER switch (13): When (b) shows "SET", the swash plate is
set to the maximum, and "RESET" indicates that the plate is set
to normal.
of a monitored value (If the Hold is selected, the HOLD part is
hatched)
REMARK
q When the dump body is set to other than Seated or the ma-
chine experiences a failure, the value (a) is set to "2: Out of
Condition" and no settings to make the pump swash plate at
the maximum are available. Make sure that the dump body is
seated or resolve the machine failure first before the setting.
q Push RETURN switch (12) to return to the standard screen
and the setting is restored to the normal setting.
PROCEDURE TO ADJUST (THROTTLE LIMIT CHECK)
"Throttle Limit Check" function arbitrarily sets the control state of KTCS and the radiator fan via the transmission controller. This
is used to check the traction force limitation function when KTCS is activated and deactivated.
Parking brake switch: (P) position
HD465-8, HD605-8 30-289

2. When the "Adjustment" screen is shown, select "Throttle Limit

Check".
"Adjustment" screen
3. When the "Throttle Limit Check" screen is shown, push the

numeral input switch (15) to display the "Numeric Input" screen.
REMARK
q Pushing any one of 0 to 9 numeral input switch displays the
"Numeric Input" screen.
q When the parking brake switch is turned to OFF position or
the machine experiences a failure, the value (b) is set to "7:
Out of Condition" and no settings for the throttle limit check
are available. Set the parking brake switch to (P) or resolve
the machine failure first before the setting.
30-290 HD465-8, HD605-8

4. When the "Numeric Input" screen is shown, use the numeric

input switch (15) to select a number (0 to 6) for which you want
to check the condition and push ENTER switch (13).
0: Normal
1: KTCS deactivated and radiator fan controlled normally
2: KTCS deactivated and radiator fan at the maximum rotation
3: KTCS deactivated and radiator fan at the minimum rotation
4: KTCS activated and radiator fan controlled normally
5: KTCS activated and radiator fan at the maximum rotation
6: KTCS activated and radiator fan at the minimum rotation
5. When the "Throttle Limit Check" screen is shown, push ENTER

switch (13) to validate the change.
(b): Setting to be changed
RETURN switch (12): Cancels the change and returns to the
"Adjustment" screen
ENTER switch (13): Validates the change
hatched)
HD465-8, HD605-8 30-291

6. Make sure that "Throttle Higher Limit Command" is changed

corresponding to the selected condition.
REMARK
q The setting is restored to the normal setting by pressing RE-
TURN switch (12) to return to "Adjustment" screen.
q "Gear shift lever position and selected gear speed list" shows
the gear speeds selected by the gear shift lever position dur-
ing the throttle limit check (condition 1 to 6).
Gear shift lever position and selected gear speed list
Gear shift lever position Gear speed

R N
N N
D F2
6 F2
5 F2
4 F2
3 F2
2 F2
L F2
30-292 HD465-8, HD605-8

PROCEDURE TO ADJUST WITH ADJUSTMENT MENU (KTCS SYSTEM CHECK)

This is shown in the "Adjustment" menu but it is not used for service.
REMARK
This menu is shown only when "KTCS" in "Option Selection" is set to
"ADD".
PROCEDURE TO ADJUST WITH ADJUSTMENT MENU (RETARDER HOIST CONTROL-

LER MEMORY RESET)
The "Retarder Hoist Controller Memory Reset" function is used when the hoist calibration settings in the retarder hoist controller
need to be reset.

switch panel to select "Retarder Hoist Controller Memory Reset".
HD465-8, HD605-8 30-293

3. When the "Retarder Hoist Controller Memory Reset" screen is

shown, push ENTER (13).
"0: Waiting for Execution"
"1: Reset completed"
RETURN switch (12): Cancels the rest and returns the display to
"Adjustment" screen
ENTER switch (13): Validates the reset
REMARK
After executing this adjustment, the hoist calibration settings are
restored to the condition at shipment.
4. Make sure that the current setting (a) is changed to "1", it means
that the reset is completed.
See "PROCEDURE TO CALIBRATION AFTER YOU ADJUST BODY POSITION SENSOR" to perform the hoist calibration.
30-294 HD465-8, HD605-8

PROCEDURE TO ADJUST WITH ADJUSTMENT MENU (KTCS VALVE SETTING)

"KTCS Valve Fixing" function is used to operate forcibly the KTCS valve that can be operated while KTCS is in operation. This
is used for testing oil pressure of KTCS circuit and bleeding air from rear brake circuit.
2. When the "Adjustment" screen is shown, select "KTCS Valve

Fixing".
"Adjustment" screen
HD465-8, HD605-8 30-295

3. When the "KTCS Valve Fixing" screen is shown, operate the

KTCS valve.
"0: Normal"
"1: ON" (The rear brake operates by operating the KTCS valve)
RETURN switch (12): Cancels the setting and returns to the "Ad-
justment" screen
ENTER switch (13): When (b) shows "SET", the KTCS valve is
enabled, and "RESET" indicates that KTCS is set to normal con-
dition.
hatched)
REMARK
q When the machine experiences a failure, the value (a) is set
to "2: Out of Condition" and KTCS cannot be operated. Make
sure to resolve the machine failure first before the setting.
q The setting is restored to the normal setting by pressing RE-
TURN switch (12) to return to "Adjustment" screen.
PROCEDURE TO CRANK WITH NO-INJECTION

If the engine is operated after long storage of the machine, it may be worn or damaged because of insufficient lubrication with
oil. To prevent this, the machine has a function to crank the engine without injecting fuel to lubricate the engine before starting it.
Setting of No-Injection cranking to be performed while the engine is stopped.
No-Injection cranking does not function while the engine is running.
This function can be selected even when the engine is running. How-
ever, if you execute No-Injection cranking, "Engine is running.
Please turn the key off once." is displayed on the screen.
Even if the confirmation screen is shown and No-Injection cranking

is operated, the function does not become effective in the following
cases. Turn the start switch OFF once to operate.
q The communication between the machine monitor and engine
controller is not normal.
q An engine start operation has been performed before the mes-
sage "No-injection cranking is possible." is shown.
30-296 HD465-8, HD605-8

1. Select "No-Injection Cranking" on "Service Menu" screen.
2. After the "No-Injection Cranking" screen is shown, confirmation

for the execution of no-injection cranking is shown. Use a switch
on the switch panel to select the action.
RETURN switch (12): Does not execute (returns the screen to
the "Service Menu" screen)
ENTER switch (13): Validates
3. If no-injection cranking (no fuel injection on every cylinder) is

enabled, "No-injection cranking is possible. Please turn the key
off after no-injection ends." is displayed on the screen. Crank the
engine with the starting motor.
NOTICE
To protect the starting motor, do not crank the engine for
longer than 20 seconds.
REMARK
While the screen is changing to the screen as shown in the fig-
ure, the screen of under preparation is shown.
4. After the cranking is completed, turn the start switch to OFF position.
You cannot change the screen described above to another screen.
HD465-8, HD605-8 30-297

PAYLOAD METER SETTING

Use "Payload Meter Setting" to change the various settings of payload meter (PLM).
PROCEDURE TO SET BY PAYLOAD METER SETTING (SETTING OF LOADING START
PAYLOAD)
Payload meter recognizes the specified payload when loading operation is started and the payload can be set up from "Setting
of Loading Start Payload". After the setting, loaded weight is shown on the machine monitor, and loaded level is displayed with
external display lamp.
NOTICE
Machine monitor and external display lamp may not operate normally if this setting is set as follows.
q When the value is less than the default value, it may fail to recognize the start of loading properly.
q When the value is more than the default value, and if bucket capacity of the machine loading is small (1 payload
is small), Predicted load display function may not operate properly.
1. Select "Payload Meter Setting" on "Service Menu" screen.
2. When the "Payload Meter Setting" screen is shown, use a switch

on the switch panel to select "Setting of Loading Start Payload".
30-298 HD465-8, HD605-8

3. When the "Setting of Loading Start Payload" screen is shown,

push the numeral input switch (15).
REMARK
Push any one of 0 to 9.
4. When (a) part is highlighted, use numeric input switch (15) to

input setting value and push ENTER switch (13).
DOWN switch (11): Enters a decimal point
RETURN switch (12): Returns to the "Payload Meter Setting"
screen
REMARK
q The default value is set to 15 %.
q The range is 5.0 to 25.5 %.
q Inputted value is not entered by pushing ENTER switch (13)
if the value is out of the range.
HD465-8, HD605-8 30-299

5. Check the changed value.
REMARK
q Entered numeric value is shown on (b).
q Payload which machine can recognize to start loading
changes.
PROCEDURE TO SET BY PAYLOAD METER SETTING (SETTING OF LOADING END

TRAVEL DIST)
With "Setting of Loading End Travel Dist", travel distance can be set in order to recognize the completion of loading.
The payload meter judges that the loading is complete when the machine runs continuously 160 m or more from where the
loading started. If soil is removed before the machine runs 160 m, the payload meter does not recognize it as removed soil.
The cycle data is not recorded correctly. If the distance between the start of loading and the dump area is less than 160 m,
perform this setting.
NOTICE
When the value is less than the default value, it may recognize it as the completion of loading during loading by mis-
take.
2. When the "Payload Meter Setting screen" is shown, use a switch

on the switch panel to select "Setting of Loading End Travel Dist".
30-300 HD465-8, HD605-8

3. When the "Setting of Loading End Travel Dist" screen is shown,

push the numeral input switch (15).
REMARK
4. When (a) part is highlighted, use numeric input switch (15) to

input setting value and push ENTER switch (13).
screen
REMARK
q The default value is set to 160 m.
q The range is 0 to 255 m.
HD465-8, HD605-8 30-301

REMARK
q Travel distance which machine can recognize to complete
loading changes.
PROCEDURE TO SET BY PAYLOAD METER SETTING (PAYLOAD OFFSET)

Use “Payload offset” to offset set payload depending on the calculation result of payload.
This function is used to make the payload closer to the value of user owned load scale.
REMARK
The payload is calculated correctly by performing the calibration.
See "Method for performing calibration" in Operation and Maintenance Manual for calibrations.

on the switch panel to select "Payload offset".
30-302 HD465-8, HD605-8

3. When the "Payload offset" screen is shown, push the numeral

(15) input switch.
REMARK
4. Use numeric input switch (15) to input setting value and push
ENTER switch (13).
UP switch (10): Switches + and -
DOWN switch (11): Enters a decimal point
screen
REMARK
q The default value is set to 0.0 t.
q The range is -0.5 to 5.0 t (Metric).
HD465-8, HD605-8 30-303

REMARK
q Payload offset changes.
PROCEDURE TO SET BY PAYLOAD METER SETTING (PAYLOAD CALCULATION METHOD)

With "Payload Calculation Method", calculating method can be selected in order for the payload meter to calculate payload
(loaded weight).
REMARK
There are 2 ways to calculate payload (loaded weight).
q "A" (Calculation at driving): It statistically calculates data collected from the place of loading to the place of dumping during trav-
eling, decides hauled payload when dumping, and saves it. "A" (Calculation at driving) is the most accurate calculation method.
q "B" (Calculation at dumping): It saves the payload when dump lever is shifted from "Float" to the position other than "Float"
at the place of dumping. Select "B" (calculation at dumping) when the traveling distance from the place of loading to the
place of dumping is short.

on the switch panel to select "Payload Calculation Method".
30-304 HD465-8, HD605-8

3. When the "Payload Calculation Method" screen is shown, use a

switch on the switch panel to select method and press ENTER
switch (13).
screen
REMARK
The default value is set to "A" (Calculation at driving).
Payload calculation method changes and the screen returns to
the "Payload Meter Setting" screen.
PROCEDURE TO SET BY PAYLOAD METER SETTING (PAYLOAD CALCULATION COM-

PENSATION)
Payload meter compensator

Commercially Total mass of maximum loading can be
A Load scale 1
available measured
Calculated payload (loaded weight) can be corrected from "Payload Calculation Compensation".
NOTICE
q The payload is calculated correctly in "Calibration" of the user menu. To make the payload closer to the value of
user owned load scale, use the "Payload offset" function for adjustment.
q To make it closer to the values of the load scale, this function can adjust it. However, this function does not im-
prove the calculation accuracy. Do not use this function for usual operation.
q Perform this correction after careful thought since the relation of suspension pressure and payload cannot be re-
turned to the condition at shipment.
q This correction directly affects calculation accuracy of payload. Be sure to observe the procedure when perform-
ing.
q The correction is performed while the machine is running at a speed of 8 km/h or higher for approximately 3 min-
utes. Secure traveling path as much as possible.
q To perform the correction correctly, before using this function, the setting values of "Payload offset" should be
restored to the default value.
HD465-8, HD605-8 30-305

1. See "PROCEDURE TO SET BY PAYLOAD METER SETTING

(PAYLOAD OFFSET)" to check the offset values of payload.
q When the offset value is 0.0 t (the payload offset is not done):
Proceed to the next step.
q When the offset value is other than 0.0 t (the payload offset
is done): Restore the offset value of payload to the default
value (0.0 t) and proceed to the next step.
2. Measure the gross machine weight with no load by using the load
meter, and write it down.
REMARK
Take notes of total mass.
3. Move the machine to the travel path.

on the switch panel to select "Payload Calculation Compensa-
tion".
30-306 HD465-8, HD605-8

6. When the "Input of Machine Weight with No Load" screen is

shown, use a switch on the switch panel to input the weight of
machine with no load and push ENTER switch (13).
UP switch (10): Moves the selection left by one item
DOWN switch (11): Moves the selection right by one item
screen
REMARK
q The unit of input values is shown in the right side of the entry
field.
q Range for inputting gross machinery weight with no load is
±15 %.
q Inputted value is not entered by pressing ENTER switch (13)
if the value is out of the range. The screen returns to the input
state of maximum digits.
HD465-8, HD605-8 30-307

7. When machine is prepared for traveling and "Start measuring of

machine weight with no load ?" screen is shown, push ENTER
switch (13).
ENTER switch (13): Moves the screen to the next screen
8. After “Start running.” is displayed, shift the gear shift lever to posi-
tion L and depress the accelerator pedal to the full stroke. Drive
the machine for approximately 3 minutes until “Measuring of
empty dump truck weight completed” is displayed.
screen
REMARK
q Validates the gross machinery weight without load and the
relation of suspension oil pressure while driving the machine
for approximately 3 minutes.
q Keep driving at a speed of 8 km/h or higher.
30-308 HD465-8, HD605-8

q When abnormality occurs during the measurement

Measurement stops, and NG screen is shown if abnormality
occurs in oil pressure sensor at each suspension or pitch an-
gle sensor. When NG screen is shown, perform troubleshoot-
ing.
9. When "Measuring of empty dump truck weight completed" is

displayed, stop the machine and press RETURN switch (12).
10. After the "Input of Machine Weight with Load" screen is shown,
perform the loading operation.
REMARK
q For maximum payload, see Operation and Maintenance
Manual or "DIAGRAM SPECIFICATION" in SPECIFICA-
TION.
q To check the loading amount, return to the standard screen
temporarily.
11. Measure the gross machine weight with maximum load by using
the load meter, and write it down.
REMARK
Take notes of total mass.
12. Move the machine to the travel path.
HD465-8, HD605-8 30-309

13. When the "Input of Machine Weight with Load" screen is shown,
use a switch on the switch panel to input the weight of machine
at maximum loading and push ENTER switch (13).
screen
REMARK
q The unit of input values is shown in the right side of the entry
field.
q Range for inputting gross machinery weight with maximum
load is ±25 %.
state of maximum digits.
14. When machine is prepared for traveling and "Start measuring of

machine weight with load ?" is displayed, push ENTER switch
(13).
30-310 HD465-8, HD605-8

15. After “Start running.” is displayed, shift the gear shift lever to posi-
tion L and depress the accelerator pedal to the full stroke. Drive
the machine for approximately 3 minutes until “Measuring of
Machine Weight with Load Completed” is displayed.
screen
REMARK
q Validate the gross machinery weight with maximum load and
the relation of suspension oil pressure while driving the ma-
chine for approximately 3 minutes.
q Keep driving at a speed of 8 km/h or higher.

Measurement stops, and NG screen is shown if abnormality
occurs in oil pressure sensor at each suspension or pitch an-
gle sensor. When NG screen is shown, perform troubleshoot-
ing.
HD465-8, HD605-8 30-311

16. Dump after "Measuring of Machine Weight with Load

Completed" is shown on the screen.
REMARK
q If the machine stops at a place where soil cannot be dumped,
push RETURN switch (12) to complete the correction of pay-
load calculation.
After you dump the soil, the correction of the calculated payload
completes and the screen goes to the "Payload Meter Setting"
screen.
PROCEDURE TO SET BY PAYLOAD METER SETTING (INCLINATION ANGLE SEN COM-

PENSATION)
"Inclination Angle Sen Compensation" can adjust the individual dispersion of pitch angle sensor and of installation.
This is used when replacing the KOMTRAX Plus controller or pitch angle sensor.
NOTICE
This correction directly affects accuracy of payload meter on a slope. Be sure to observe the procedure when per-
forming.
1. Move the machine to the level ground.
REMARK
Allowable value of slope angle of the ground (reference): -5 to 5 ˚
30-312 HD465-8, HD605-8


on the switch panel to select "Inclination Angle Sen Compensa-
tion".
4. When voltage of "1st" in "Correction of inclination sensor"

becomes stable, push ENTER switch (13).
screen
HD465-8, HD605-8 30-313


If abnormality occurs in pitch angle sensor, NG screen is
shown. When NG screen is shown, perform troubleshooting.
5. Reverse the direction of the machine by 180 ˚ and stop the
machine at the previous position.
6. When voltage of "2nd" in "Correction of inclination sensor"

becomes stable, push ENTER switch (13).
screen
30-314 HD465-8, HD605-8

7. When average value of "1st" and "2nd" is shown on "Standard

level value" (a), push ENTER switch (13).
screen
ENTER switch (13): When correction of pitch angle sensor is
completed, the screen returns to the "Payload Meter Setting"
screen
PROCEDURE TO SET BY PAYLOAD METER SETTING (SETTING OF RANGE OF EXTERNAL

LAMPS)
"Setting of Range of External Lamps" can change the setting of load level on external display lamp.
NOTICE
If the weight of unloaded machine increases by modifications, it needs to decrease the increment from maximum load-
ing to avoid overloading. In this case, use this setting and change the setting of external display lamp so as not to
load over maximum loading with the modified loader.
Example: The unloaded machine weight of HD465-8 increases 2 t
Initial status Modified

Unloaded machine weight (t) 48.5 50.5
Max. payload (t) 55 53
Green (%) 50 (*1) 48 (*1) (*2)
External display lamp setting Yellow (%) 90 (*1) 87 (*1) (*2)
Red (%) 105 (*1) 101 (*1) (*2)
*1 Value for max. payload 55 t (Specification value)

*2 Setting value for max. payload (53 t) of the modified machine. The lamp value is green 50 %, yellow 90 %, and red 105 %
of the value shown before the machine is modified.
HD465-8, HD605-8 30-315


on the switch panel to select "Setting of Range of External
Lamps".
3. When the "Setting of Range of External Lamps" screen is shown,

use a switch on the switch panel to select the display range of
each lamp and push ENTER switch (13).
screen
MENU switch (14): Changes all the input value to previous val-
ues, and you can set the top digit of "G".
REMARK
q The default value is set as follows.
"G" (green lamp): 50 % of maximum loading
"A" (yellow lamp): 90 % of maximum loading
"R" (red lamp): 105 % of maximum loading (HD465)
:100 % of maximum load (HD605)
q Range for inputting is 0 to 130 % of maximum loading.
But the value of "A" (yellow lamp) should be set more than
"G" (green lamp). The value of "R" (red lamp) should be set
more than "A" (yellow lamp).
state of the top digit of "G".
Payload setting is changed to display the load level on external display lamp and the screen returns to the "Payload Meter
Setting" screen.
30-316 HD465-8, HD605-8

PROCEDURE FOR MANUAL SNAP SHOT

This function is used to record the data, which are used in the Pm clinic, testing and adjusting, to the KOMTRAX Plus controller.
When collecting the data periodically for such as the Pm clinic, the machine needs to be handled in the regular method defined
by the quick Pm, however, if you collect the data which are necessary for testing and adjusting and such, the machine handling
method is not defined.
For handling the machine for Quick Pm, see "PERFORMING QUICK Pm".
REMARK
q The data recorded in the KOMTRAX Plus controller are recorded with Manual Snap Shot and the data recorded automat-
ically when the specified error occurs. The data is recorded a maximum of 9 times.
q When the data of maximum number of times are recorded in the KOMTRAX Plus controller, data will not record when Man-
ual Snap Shot is performed.
q Before Manual Snap Shot is performed, download the data recorded in the KOMTRAX Plus controller to the PC and delete
the data in the KOMTRAX Plus controller.
q To use the data which have been recorded with the manual snap shot, you need to load them to a personal computer. For
downloading of data, see "DOWNLOAD OF KOMTRAX Plus CONTROLLER DATA".
1. See "DOWNLOAD OF KOMTRAX Plus CONTROLLER DATA" to download the data recorded in the KOMTRAX Plus
controller to the PC.
REMARK
After downloading the data to the PC, delete the data in the KOMTRAX Plus controller.
2. Select "Manual Snap Shot" from the "Service Menu" screen.
3. When the "Manual Snap Shot" screen is shown, check that the
oil temperature and coolant temperature are within the range of
testing condition, and push UP switch (10).
UP switch (10): Proceeds to the confirmation screen to start re-
cording
HD465-8, HD605-8 30-317

4. When "Start Snapshot?" is shown, push ENTER switch (13).

RETURN switch (12): Stops recording, and returns to the "Ser-
vice Menu" screen
ENTER switch (13): Starts to record
5. The data recording has been started. Operate the machine until
recording finishes.
REMARK
q The progress of the recording can be checked with "Dura-
tion" and the progress bar whose color change per 30 sec-
onds on the machine monitor.
q The color of progress bar is green for 5 minutes from the start
of recording. The data sampling interval is every 10 seconds.
(10 lights in progress bar from the left: (a))
q The color of progress bar is yellow after 5 minutes has
passed until the finish of sampling. The data sampling inter-
val is every 1 second.
(From 11th through 15th lights in progress bar: (b))
q For handling the machine for Quick Pm, see "PERFORMING
QUICK Pm".
q To cancel Manual Snap Shot, push DOWN switch (11).
When "Stop Snapshot?" is shown, push ENTER switch. The
display returns to the screen of step 3.
If "Snapshot is completed." is shown after 7 minutes and 30 sec-

onds have passed from the start of recording, the data recording
has been completed. Load the data to a personal computer, and
utilize them for diagnosis of the machine.
REMARK
q The data of "Manual Snap Shot" is recorded in the KOM-
TRAX Plus controller only one time. The data is written over
when "Manual Snap Shot" is performed continuously. Make
sure to download the data to the PC after you perform "Man-
ual Snap Shot".
30-318 HD465-8, HD605-8

q For downloading of data, see "DOWNLOAD OF KOMTRAX Plus CONTROLLER DATA".

q After 3 seconds passes since the recording has been completed, the screen returns to the starting screen of "Manual
Snap Shot".
q For the data that can be recorded with Manual Snap Shot, see "The list of Manual Snap Shot".
The list of Manual Snap Shot
No. Item
1 Calendar (Date and time)
2 Engine speed
3 Fuel injection
4 Crankcase pressure
5 Exhaust temperature
6 Engine oil pressure
7 Engine oil temperature
8 Engine coolant temperature
9 Atmospheric temperature
10 Boost pressure
11 Intake air temperature
12 Throttle position
13 Hoist lever status
14 Torque converter oil temperature
15 T/M Output Shaft Speed
16 Shift gear
17 Lockup signal
18 Retarder oil temperature (Rear)
19 Brake oil pressure (Front)
20 Brake oil pressure (Rear)
21 Brake output (Rear)
22 Foot brake position
23 Inclination angle
24 Payload
HD465-8, HD605-8 30-319

KOMTRAX SETTINGS MENU

PROCEDURE TO CONFIRM KOMTRAX SETTINGS (TERMINAL STATUS)
The setting and operating state of KOMTRAX can be checked by using the menu of KOMTRAX Settings.
"Terminal Setting State" is used to check the setting condition of the KOMTRAX terminal.
1. Select "KOMTRAX Settings" on "Service Menu" screen.
2. After the "KOMTRAX Settings" screen is displayed, use a switch

on the switch panel to select "Terminal Setting State".
REMARK
3. After the "Terminal Setting State" screen is shown, the following

items of information are shown.
Terminal Type: Model name of the KOMTRAX communication
modem
KOMTRAX Communication: State of radio station establishment
GMT Time: Greenwich Mean Time (add 9 hours to it for Japan
time)
RETURN switch (12): Returns to the "KOMTRAX Settings"
screen
30-320 HD465-8, HD605-8

PROCEDURE TO CONFIRM KOMTRAX SETTINGS (GPS AND COMMUNICATION STA-

TUS)
The setting and operating state of KOMTRAX can be checked by using the menu of KOMTRAX settings.
"GPS & Communication Status" is used to check the positioning and communication condition of KOMTRAX terminal.

on the switch panel to select "GPS & Communication State".
REMARK
3. After the "GPS & Communication State" screen is shown, the

following items of information are shown.
Positioning: GPS positioning state
Communication: Communication environment and connection
state of the communication modem
Number of message(s) not yet sent: Number of mails that are
saved on the machine monitor and have not yet been transmitted
screen
HD465-8, HD605-8 30-321

PROCEDURE TO CONFIRM KOMTRAX SETTINGS (MODEM STATUS)

The setting and operating state of KOMTRAX can be checked by using the menu of KOMTRAX Settings.
"Modem Information" is used to check IMSI and IMEI of the KOMTRAX communication modem.

on the switch panel to select "Modem Information".
REMARK
3. "IMSI" and "IMEI" are displayed.

screen
PROCEDURE TO DISPLAY SERVICE MESSAGE

Special messages for the technician sent from KOMTRAX base station (a distributor) can be checked with this function.
If a received message includes a setting for reply, a return mail can be sent with the numeral input switches as well.
30-322 HD465-8, HD605-8

1. Select "Service Message" on "Service Menu screen".
2. Displaying message
q Display of message (read only)
If there is a message, its contents are shown. If there is no
message, "No message." is shown.
REMARK
q The message is different from that sent to the opera-
tor in the operator mode.
q Since this message is only for the technician, the
message monitor is not shown as it is displayed in the
operator mode.
q Display of message (with message return function)

If a message provides the Numeric Input line under the text,
input a proper number with a switch on the switch panel and
enter it, and the information is returned to the KOMTRAX
base station.
screen
ENTER switch (13): Validates and returns the inputted value.
REMARK
q The message is different from that sent to the opera-
tor in the operator mode.
q Since this message is only for the technician, the
message monitor is not shown as it is displayed in the
operator mode.
HD465-8, HD605-8 30-323

PROCEDURE FOR STARTING UP KOMTRAX TERMINAL 30 TEST AND ADJUST
PROCEDURE FOR STARTING UP KOMTRAX TERMINAL

PROCEDURE FOR STARTING UP KOMTRAX TERMINAL
Perform the following procedure when using KOMTRAX.
1. KOMTRAX key person performs "Machine Registration" by using KOMTRAX client PC.
2. Perform "KOMTRAX Communication Inspection".
q For operation procedures, see "Global KOMTRAX Web Reference Manual (For Key Person)".
q Operating the KOMTRAX client PC requires the KOMTRAX key person authority of each distributor. Therefore, consult
the KOMTRAX key person before using it.
When KOMTRAX Plus controller is replaced
Observe the following when replacing KOMTRAX Plus controller and using it again.
1. Our technician provides a new controller, and records the part number and serial number.
2. Our technician replaces the controller, and perform “KOMTRAX Communication Inspection”. Our technician notifies
KOMTRAX key person of the completion of inspection work and new controller information.
3. KOMTRAX key person performs "Terminal Replacement" by using KOMTRAX client PC.
4. KOMTRAX key person fills in required items on "Terminal Replacement Sheet", and send it by email to KOMTRAX support
center via KOMTRAX administrator in the subsidiary.
q For details, see "Global KOMTRAX Web Reference Manual (For Key Person)".
q Operating the KOMTRAX client PC requires the KOMTRAX key person authority of each distributor. Therefore, consult
the KOMTRAX key person before using it.
When KOMTRAX terminal is replaced
Observe the following when replacing KOMTRAX terminal and using it again.
REMARK
When KOMTRAX terminal is replaced, "KOMTRAX Communication Inspection" does not need to be performed.
1. Our technician provides a new terminal, and records the part number and serial number.
2. Our technician replaces the terminal. Our technician notifies KOMTRAX key person of the completion of inspection work
and new terminal information.
3. KOMTRAX key person fills in required items on "Terminal Replacement Sheet", and send it by email to KOMTRAX support
center via KOMTRAX administrator in the subsidiary.
REMARK
Upon receiving "Terminal Replacement Sheet", KOMTRAX support center replaces the KOMTRAX TERMINAL on the server.
Machine side inspection for KOMTRAX Communication opening
q KOMTRAX communication inspection must be done to check whether normal communication is available from the terminal
when the KOMTRAX Plus controller is replaced or operation of KOMTRAX terminal is started.
q By performing this inspection, KOMTRAX starts communication.
q GPS and data communication are checked during the KOMTRAX Communication Inspection. Accordingly, it is preferable
to place the machine under the open sky where radio wave from the satellite is not blocked. The opening inspection may
not be completed when the machine is placed indoor where radio wave from the satellite is blocked.
1. Check the machine for communication inspection
Observe the following when checking if KOMTRAX Communication Inspection is to be performed or not.
30-324 HD465-8, HD605-8

30 TEST AND ADJUST PROCEDURE FOR STARTING UP KOMTRAX TERMINAL
1) On the "Service Menu" screen, use a switch on the

monitor panel to select "KOMTRAX Settings".
2) When the "KOMTRAX Settings" screen is shown, use a

switch on the monitor panel to select "Terminal Setting
State".
3) When the "Terminal Setting State" is shown, check

"KOMTRAX Communication".
When "KOMTRAX Communication" is shown as
"KOMTRAX Communication not Open", perform step 2.
When it is shown as "Already Open", communication
inspection is unnecessary.
2. Perform communication inspection
Observe the following when performing communication inspec-
tion.
1) On the "Service Menu" screen, use a switch on the

monitor panel to select "KOMTRAX Settings".
2) When the "KOMTRAX Settings" screen is shown, use a

switch on the monitor panel to select "GPS and Commu-
nication State".
HD465-8, HD605-8 30-325

3) When the "GPS and Communication State" screen is

shown, push numeral input switches (1), (2), and (3) in
order while pushing DOWN switch (11) on the monitor
panel.
4) After "Are you sure you want to inspect?" is displayed,

execute the inspection with the switch on the monitor
panel.
RETURN switch (12): Returns to the "GPS and Commu-
nication State" screen
ENTER switch (13): Performs communication inspection
30-326 HD465-8, HD605-8

30 TEST AND ADJUST PROCEDURE FOR STARTING UP KOMTRAX TERMINAL
5) The screen displays the state of KOMTRAX Communica-

tion inspection. Check on this screen that all item are
"OK".
"Modem": "OK" is shown when communication area is
confirmed.
"GPS": "OK" is shown when it acquires GPS data.
"Transmission": "OK" is shown when message is trans-
mitted normally.
"Inspection State": When all of "Modem", "GPS", and
"Transmission" are "OK", "OK" is shown in "Inspection
State".
q While waiting for all items to be "OK", operation such as turning the start switch to OFF position or starting the
engine will not be a problem.
If there is nothing abnormal, the communication inspection finishes automatically. Select "Service Menu",
"KOMTRAX Settings" → "Terminal Setting State" to make sure that "Already Open" is indicated for "KOMTRAX
Communication".
q The communication inspection may not be completed when the machine is placed indoor where radio wave
from the satellite is blocked.
6) When all items are "OK", the "Inspection finished
normally." screen is shown.
Push ENTER switch (13). "GPS and Communication
State" appears, and the communication inspection for
machine side is completed.
Other than the above, perform step 3.
3. Troubleshooting when the communication inspection is finished
unsuccessfully
q If any of 1) to 5) in step 2 is finished unsuccessfully, perform
inspection from 1) in step 2.
q If 6) in step 2 is finished unsuccessfully, following problems are suspected.
Troubleshooting when the failure occurs
Phenomenon Cause Required action

There is an obstacle in between the Check the GPS antenna for abnormality and there is no obstacle
machine and GPS satellite around.
GPS does not
become OK Check for the connection of the GPS antenna and the connector
GPS antenna cable is not connected
of extension cable, the extension cable and the connector of the
to the machine, or they are loose
KOMTRAX Plus controller. If the connection is loose, secure it.
There is an obstacle in between the q Move to an open place, then perform the inspection.
machine and communication satellite q Check KOMTRAX communication antenna for abnormality.
Check for the connection of the KOMTRAX communication
KOMTRAX communication antenna
antenna and the connector of extension cable, the extension
cable is not connected to the
Modem does not cable and the connector of the KOMTRAX terminal. If the
terminal, or they are loose
become OK connection is loose, secure it.
KOMTRAX terminal and KOMTRAX
Plus controller are not connected to
Check for the connection. If the connection is loose, secure it.
machine side wiring harness, or they
are loose.
4. After troubleshooting, perform 1) in step 2 again.
REMARK
When the problems are not solved, contact your KOMTRAX support center.
HD465-8, HD605-8 30-327

30-328 HD465-8, HD605-8

30 TEST AND ADJUST DEFAULT SETTING OF KOMTRAX Plus CONTROLLER
DEFAULT SETTING OF KOMTRAX Plus CONTROLLER

Tools to set the default of KOMTRAX Plus controller

q Notebook type
Commercially
A Personal computer 1 q Windows® 7/8/8.1 based
available
B LAN cable 1
C - Initial Configuration Tool 1 Software for setting KOMTRAX Plus controller
E - Data Conversion Tool 1 Software for converting the downloaded data
NOTICE
The following is the work order for each setting. For details of each setting, see Operation and Maintenance Manual
for each tool.
Obtain each tool (software) from "KOMTRAX Support, KLTD".
E-mail address: [email protected]
After assembling the machine, be sure to initialize KOMTRAX Plus controller.
PROCEDURE FOR SETTING WITH DEFAULT SETTING OF KOMTRAX Plus CONTROL-
LER
1. Install default setting tool C to personal computer A. For details, see Operation and Maintenance Manual for default setting
tool C.
2. Install data collection tool D to personal computer A. For details, see Operation and Maintenance Manual for data collection
tool D.
3. Install data conversion tool E to personal computer A. For details, see Operation and Maintenance Manual for data conver-
sion tool E.
4. Set the IP address to personal computer A.
REMARK
The IP address of personal computer A must be set since the default setting tool C and the data collection tool D perform
the setting of KOMTRAX Plus controller and the data downloading through LAN cable.
1) Open "Control Panel" from Start Menu.
2) Open "Network And Sharing Center" and "Change Adapter Settings" on the control panel.
3) Right-click the LAN adapter of mounted LAN port (local area connection), and open "Property".
4) Push the button of "Property" on the displayed dialog.
5) Select "Internet Protocol Version 4 (TCP/IPv4)" on the displayed dialog, and push the button of "Property".
6) Select "Use the following IP address", input the following value, and push "OK".
IP address: 192.168.0.240
Subnet mask: 255.255.255.0
Default gateway: 192.168.0.200
REMARK
The inputting into the DNS server is not required.
HD465-8, HD605-8 30-329

DEFAULT SETTING OF KOMTRAX Plus CONTROLLER 30 TEST AND ADJUST
5. Connect personal computer A and application rewrite service

connector (1) in the operator's cab by LAN cable B.
REMARK
If the setting is started immediately after the start switch is set to
the ON position, the setting may not be made correctly. Start the
setting about 1 minute after the start switch is set to the ON po-
sition.
7. Configure the locale-specific setting of KOMTRAX Plus
controller. For details, see Operation and Maintenance Manual
for default setting tool C.
8. Configure the setting of the customer's machine control No. (unit No.). For details, see Operation and Maintenance Manual
REMARK
q Configure the setting of the customer's machine control No. (unit No.) as necessary since it is optional.
q The customer's machine control No. (unit No.) is used for display on KOMTRAX server after the setting is configured.
9. Perform the setting of the time (time zone) and the daylight saving time to KOMTRAX Plus controller for the delivery desti-
nation. For details, see Operation and Maintenance Manual for default setting tool C.
10. Restart KOMTRAX Plus controller. For details, see Operation and Maintenance Manual for default setting tool C.
REMARK
q It is not necessary to turn the start switch of machine to OFF position.
q Each setting is applied after KOMTRAX Plus controller is restarted.
11. Make sure that the settings are applied with default setting tool C.
REMARK
If there is no error message on the screen of default setting tool C, the settings are applied.
12. Configure the setting of KOMTRAX function of KOMTRAX Plus controller. For details, see Operation and Maintenance
Manual for default setting tool C.
13. Register the machine to KOMTRAX server.
REMARK
For details of registration work, ask KOMTRAX operations administrator.
14. Download the default data of KOMTRAX Plus controller. For details, see Operation and Maintenance Manual for data
collection tool D.
REMARK
q Downloaded "K File" (file having extension "K") is used for registration of WebCARE.
q "K File" (file having extension "K") downloaded after Quick Pm can be used for registration of WebCARE as well.
15. Make sure that downloading is completed with data collection tool D.
REMARK
If there is no error message on the screen of data collection tool D, downloading is completed.
17. Disconnect the LAN cable B.
18. Convert the downloaded default data to a CSV file, check its contents, and register it to WEBCARE. For details, see Oper-
ation and Maintenance Manual for data conversion tool E.
The default setting of KOMTRAX Plus controller has been completed.
After completing default setting of KOMTRAX Plus, register the machine to "EQP Care" server.
For details of registration, ask "EQP Care" support desk via the person in charge of "EQP Care" in the subsidiary.
30-330 HD465-8, HD605-8

30 TEST AND ADJUST SETTING DEFAULT OF WIRELESS LAN MODEM
SETTING DEFAULT OF WIRELESS LAN MODEM

Tools to set the default of wireless LAN modem

q Notebook type
q Windows® 7/8/8.1 based
Commercially
A Personal computer 1 q Equipped with wireless LAN port having ac-
available
cess point function
q Recommended product: "Panasonic Let's
note" AX/SX/MX Series
B LAN cable 1
C - Network Configuration Tool 1 Software for setting up a wireless LAN modem
NOTICE
for each tool.
When downloading KOMTRAX Plus data through wireless LAN, be sure to perform this default setting.
After delivering the machine, be sure to check the communication of wireless LAN modem.
PROCEDURE FOR SETTING DEFAULT OF WIRELESS LAN MODEM
1. Install the network setting tool C to personal computer A. For details, see Operation and Maintenance Manual for network
setting tool C.
REMARK
The IP address of the personal computer A must be set since default setting of wireless LAN modem is performed through
LAN cable.
IP address: 192.168.0.240
Subnet mask: 255.255.255.0
REMARK
HD465-8, HD605-8 30-331

SETTING DEFAULT OF WIRELESS LAN MODEM 30 TEST AND ADJUST
3. Connect personal computer A and application rewrite service

connector (1) in the operator's cab by LAN cable B.
REMARK
If the setting is started immediately after the start switch is set to the ON position, the setting may not be made correctly.
Start the setting about 1 minute after the start switch is set to the ON position.
5. Configure the setting of the wireless output of wireless LAN modem and transmission power. For details, see Operation
and Maintenance Manual for network setting tool C.
q Setting of the wireless output:
The wireless output is disabled at shipment, change the setting and enable the wireless output.
q Setting of transmission power:
The transmission power must be set to the value which conforms to the regulation of the country where the machine is
used. Set the transmission power to the value which conforms to the regulation of the country.
After changing the default setting of the wireless LAN modem, check the communication of the wireless LAN modem.
PROCEDURE TO CHECK WIRELESS LAN MODEM COMMUNICATION
Network setting tool C is used to check the wireless LAN modem communication.
Check the wireless LAN modem communication in a place where the wireless LAN modem that runs in the personal computer
A and the machine can communicate with each other.
REMARK
The IP address of the personal computer A must be set since wireless LAN modem communication is checked through the
wireless LAN to see if it is established.
IP address: 10.1.0.100
Subnet mask: 255.0.0.0
REMARK
Inputting into neither default gateway nor DNS server is required.
3. Set the access point function for personal computer A.
1) Enable the access point function, and set SSID and encryption to personal computer A. For details, see Operation
After setting the access point function of personal computer A, the wireless LAN port of personal computer A and the wire-
less LAN modem of the machine are connected automatically.
4. Check the wireless LAN modem communication. For details, see Operation and Maintenance Manual for network setting
tool C.
30-332 HD465-8, HD605-8

30 TEST AND ADJUST DOWNLOAD KOMTRAX Plus CONTROLLER DATA
DOWNLOAD KOMTRAX Plus CONTROLLER DATA

Tools to download the KOMTRAX Plus controller data

q Notebook type
Commercially
available
cess point function
B LAN cable 1
NOTICE
for each tool.
PROCEDURE FOR DOWNLOAD OF KOMTRAX Plus CONTROLLER DATA
The following 3 methods are used to download KOMTRAX Plus controller data.
REMARK
q In wireless LAN specification, you can use either wireless LAN or service connector for downloading the data.
q In ground level specification, you can use either ground level download connector or service connector for downloading the
data.
Method for downloading data through the wireless LAN (wireless LAN specification)
Download data through the wireless LAN.
Download data in a place where the wireless LAN modem that runs in the personal computer A and the machine can commu-
nicate with each other.
setting tool C.
REMARK
Since data is downloaded through the wireless LAN, IP address must be set to personal computer A.
REMARK
HD465-8, HD605-8 30-333

DOWNLOAD KOMTRAX Plus CONTROLLER DATA 30 TEST AND ADJUST
3. Turn the switch (2) to ON position.
REMARK
q KOMTRAX Plus controller starts up, and LED lamp (3) lights
up by turning switch (2) to ON position even when the start
switch of the machine is in OFF position.
q If the download is not performed within 15 minutes after
switch (2) is set to ON position, the machine automatically
becomes OFF state even if switch (2) is in ON position, and
LED lamp (3) lights off.
q KOMTRAX Plus controller can be started up also by setting
the start switch of the machine to ON position instead of setting switch (2) to ON position.
4. Make sure that LED lamp (3) illuminates.
REMARK
While LED lamp (3) is off, the data cannot be downloaded.
After setting the access point function to personal computer A, the wireless LAN modem of personal computer A and that
of machine are connected automatically.
6. Download the data of Quick Pm, testing, and adjustment from KOMTRAX Plus controller. For details, see Operation and
Maintenance Manual for data collection tool D.
7. Turn the switch (2) to OFF position.
NOTICE
The switch (2) must be in OFF position, otherwise the battery may be discharged.
Convert the data downloaded from KOMTRAX Plus controller into CSV file by using data conversion tool E, and use them for
troubleshooting of machine.
30-334 HD465-8, HD605-8

30 TEST AND ADJUST DOWNLOAD KOMTRAX Plus CONTROLLER DATA
Method for downloading the data through the ground level download connector (ground level download specifica-
tion)
Download data through the ground level download connector on the left side of machine.
setting tool C.
REMARK
IP Address must be set to personal computer A since data is downloaded through LAN cable B.
REMARK
3. Connect personal computer A and ground level download connector (1) by LAN cable B.
4. Turn the switch (2) to ON position.
REMARK
q KOMTRAX Plus controller starts up, and LED lamp (3) lights
up by turning switch (2) to ON position even when the start
switch of the machine is in OFF position.
q If the download is not performed within 15 minutes after
switch (2) is set to ON position, the machine automatically
becomes OFF state even if switch (2) is in ON position, and
LED lamp (3) lights off.
q KOMTRAX Plus controller can be started up also by setting
the start switch of the machine to ON position instead of setting switch (2) to ON position.
5. Make sure that LED lamp (3) illuminates.
REMARK
While LED lamp (3) is off, the data cannot be downloaded.
6. Download the data of Quick Pm, testing, and adjustment from KOMTRAX Plus controller. For details, see Operation and
Maintenance Manual for data collection tool D.
7. Turn the switch (2) of the download connector to OFF position, then disconnect LAN cable B.
NOTICE
The switch (2) must be in OFF position, otherwise the battery may be discharged.
HD465-8, HD605-8 30-335

DOWNLOAD KOMTRAX Plus CONTROLLER DATA 30 TEST AND ADJUST
Procedure to download data through the service connector

Download data through the service connector for rewriting application in the operator's cab.
setting tool C.
REMARK
IP Address must be set to personal computer A since data is downloaded through LAN cable B.
IP address: 192.168.0.240
Subnet mask: 255.255.255.0
REMARK
3. Connect the personal computer A and service connector (1) with
LAN cable B.
5. Download the data of Quick Pm, testing, and adjustment from
KOMTRAX Plus controller. For details, see Operation and Main-
tenance Manual for data collection tool D.
REMARK
If the downloading is performed immediately after the start switch
is set to the ON position, the downloading may not be finished
normally. Start the downloading about 1 minute after the start
switch is set to the ON position.
30-336 HD465-8, HD605-8

30 TEST AND ADJUST ADJUST WHEN KOMTRAX Plus CONTROLLER IS REPLACED
ADJUST WHEN KOMTRAX Plus CONTROLLER IS REPLACED

Devises to adjust the KOMTRAX Plus controller when it is replaced

q Notebook type
Commercially
A Personal computer 1 q Windows® 7/8/8.1 based
available
B LAN cable 1
C - Initial Configuration Tool 1 Software for setting KOMTRAX Plus controller
NOTICE
for each tool.
Perform this adjustment always when the KOMTRAX Plus controller is replaced.
PROCEDURE TO ADJUST KOMTRAX Plus CONTROLLER WHEN REPLACED
The work before the replacement
1. Install default setting tool C to personal computer A. For details, see Operation and Maintenance Manual for default setting
tool C.
2. Install data collection tool D to personal computer A. For details, see Operation and Maintenance Manual for data collection
tool D.
3. Install the data conversion tool E to personal computer A. For details, see Operation and Maintenance Manual for data
conversion tool E.
REMARK
The IP address of personal computer A must be set since the default setting tool C and the data collection tool D perform
the setting of KOMTRAX Plus controller and the data downloading through LAN cable.
IP address: 192.168.0.240
Subnet mask: 255.255.255.0
REMARK
HD465-8, HD605-8 30-337

ADJUST WHEN KOMTRAX Plus CONTROLLER IS REPLACED 30 TEST AND ADJUST

LAN cable B.
7. Download the data of KOMTRAX Plus controller before replace-
ment. For details, see Operation and Maintenance Manual for data
collection tool D.
REMARK
If the downloading is performed immediately after the start switch
is set to the ON position, the downloading may not be finished
normally. Start the downloading about 1 minute after the start
switch is set to the ON position.
REMARK
9. Perform the loading of the setting information of KOMTRAX Plus controller. For details, see Operation and Maintenance
REMARK
If the loading of the setting information of KOMTRAX Plus controller failed, the unique setting for the machine can be con-
figured by using default setting tool C.
Replace the KOMTRAX Plus controller assembly. For details, see DISASSEMBLY AND ASSEMBLY, "REMOVE AND IN-
STALL KOMTRAX plus CONTROLLER ASSEMBLY".
The work to do after the replacement
LAN cable B.
3. Write the setting information to the KOMTRAX Plus controller.
For details, see Operation and Maintenance Manual for default
setting tool C.
REMARK
q If the loading of the setting information failed before the re-
placement of KOMTRAX Plus controller, configure the
unique setting for the machine by using default setting tool C.
q To configure the unique setting for the machine with the road analysis function, select a machine model "HD465-8-RA"
or "HD605-8-RA". If you select a machine model name without "-RA", the road analysis function cannot be used.
q If the setting is started immediately after the start switch is set to the ON position, the setting may not be made correctly.
Start the setting about 1 minute after the start switch is set to the ON position.
4. Configure the locale-specific setting of KOMTRAX Plus controller. For details, see Operation and Maintenance Manual for
default setting tool C.
5. Configure the setting of the customer's machine control No. (unit No.). For details, see Operation and Maintenance Manual
REMARK
q Configure the setting of the customer's machine control No. (unit No.) as necessary since it is optional.
q The customer's machine control No. (unit No.) is used for display on KOMTRAX server after the setting is configured.
6. Perform the setting of the time (time zone) and the daylight saving time to KOMTRAX Plus controller for the delivery desti-
nation. For details, see Operation and Maintenance Manual for default setting tool C.
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30 TEST AND ADJUST ADJUST WHEN KOMTRAX Plus CONTROLLER IS REPLACED
7. Restart KOMTRAX Plus controller. For details, see Operation and Maintenance Manual for default setting tool C.
REMARK
q It is not necessary to turn the start switch of machine to OFF position.
q Each setting is applied after KOMTRAX Plus controller is restarted.
8. Make sure that the settings are applied with default setting tool C.
REMARK
If there is no error message on the screen of default setting tool C, the settings are applied.
9. Configure the setting of KOMTRAX function of KOMTRAX Plus controller. For details, see Operation and Maintenance
10. Download the data of KOMTRAX Plus controller after replacement. For details, see Operation and Maintenance Manual
for data collection tool D.
REMARK
q Downloaded "K File" (file having extension "K") is used for registration of WebCARE.
q "K File" (file having extension "K") downloaded after Quick Pm can be used for registration of WebCARE as well.
REMARK
14. Convert the downloaded default data to a CSV file, check its contents, and register it to WEBCARE. For details, see Oper-
ation and Maintenance Manual for data conversion tool E.
The adjustment of KOMTRAX Plus controller has been completed.
HD465-8, HD605-8 30-339

ADJUST WHEN WIRELESS LAN MODEM IS REPLACED 30 TEST AND ADJUST
ADJUST WHEN WIRELESS LAN MODEM IS REPLACED

Devises to adjust the wireless LAN modem when it is replaced

q Notebook type
Commercially
available
cess point function
B LAN cable 1
q Output: 24 V (1 A)
Commercially PoE power feeding adapter, or PoE q Recommended products:
D 1
available power feeding injector "Ubiquiti Networks, Inc."
POE-24-2W, POE-24-2W-G
NOTICE
for each tool.
Perform this adjustment always when the wireless LAN modem is replaced.
PROCEDURE FOR ADJUSTMENT WHEN WIRELESS LAN MODEM IS REPLACED
The work before the replacement
setting tool C.
REMARK
The IP address of the personal computer A must be set since default setting of wireless LAN modem is performed through
LAN cable.
IP address: 192.168.0.240
Subnet mask: 255.255.255.0
REMARK
3. Connect the LAN port for power feeding of PoE adapter D and the LAN port of wireless LAN modem prepared for replace-
ment by using LAN cable B.
4. Connect the LAN port not for power feeding of PoE adapter D and the LAN port of personal computer A by using LAN cable
B.
30-340 HD465-8, HD605-8

30 TEST AND ADJUST ADJUST WHEN WIRELESS LAN MODEM IS REPLACED
NOTICE
Do not connect personal computer A to the LAN port for power feeding of PoE adapter D, as this may cause a fail-
ure.
5. Configure the setting of the wireless output of wireless LAN modem and transmission power. For details, see Operation
q Setting of the wireless output:
The wireless output is disabled at shipment, change the setting and enable the wireless output.
q Setting of transmission power:
The transmission power must be set to the value which conforms to the regulation of the country where the machine is
used. Set the transmission power to the value which conforms to the regulation of the country.
Replace the wireless LAN unit assembly. For details, see "REMOVE AND INSTALL WIRELESS LAN UNIT ASSEMBLY".
The work to do after the replacement
Make sure that the communication of the wireless LAN modem is established after the wireless LAN unit assembly has been
installed.
Network setting tool C is used to check the wireless LAN modem communication.
Make sure that the communication of the wireless LAN modem is established in a place where the wireless LAN port for the
personal computer A and that of the machine can communicate with each other.
REMARK
The IP address of the personal computer A must be set since wireless LAN modem communication is checked through the
wireless LAN to see if it is established.
3) Right-click the LAN adapter (Local area connection) of Ethernet port which is mounted, and open "Property".
REMARK
After setting the access point function of personal computer A, the wireless LAN port of personal computer A and the wire-
less LAN modem of the machine are connected automatically.
4. Check the wireless LAN modem communication. For details, see Operation and Maintenance Manual for network setting
tool C.
HD465-8, HD605-8 30-341

ADJUST REARVIEW CAMERA ANGLE 30 TEST AND ADJUST
ADJUST REARVIEW CAMERA ANGLE

PROCEDURE TO ADJUST REARVIEW CAMERA ANGLE
k Be sure to adjust the rearview camera before starting work.
If the rearview camera is not adjusted properly, you cannot secure the visibility and may be injured or may lead to
a serious personal injury or death.
k When adjusting the angle of the rearview camera, prepare a scaffold first in order to provide a safe working plat-
form.
k Install only the Komatsu genuine camera.
1. Make sure that the images on the rearview monitor are normal as
shown in the figure. Then, confirm that the machine width guide
line (g) matches with the tire outside width (c) and the distance
guide line (h) matches with the line of dump body rear end (d).
2. If the image on the rearview monitor is not aligned correctly,

loosen mounting bolts (1) (3 places), and adjust the mounting
angle of the rearview camera.
The mounting angle of rearview camera can be adjusted within
the range of 25 to 55 ˚ downward to the horizontal direction of 0 ˚.
3. Check the rearview camera angle again.
4. After adjustment, tighten mount bolts (1) of the rearview camera.
30-342 HD465-8, HD605-8

30 TEST AND ADJUST ADJUST OPTICAL AXIS OF HEAD LAMP
ADJUST OPTICAL AXIS OF HEAD LAMP

k If the optical axis is adjusted wrongly, the head lamps may rattle, and you cannot secure the visibility and may
lead to a serious personal injury or death.
k Install only the Komatsu genuine head lamps.
k When adjusting the optical axis of the head lamps, prepare a scaffold first in order to provide a safe working plat-
form.
REMARK
q Perform this adjustment only when the head lamps are replaced or if it is required.
q This adjustment is applied to both low beam and high beam of the head lamps.
PROCEDURE TO ADJUST OPTICAL AXIS OF HEAD LAMP
PROCEDURE TO ADJUST LEFT AND RIGHT OPTICAL AXES OF RIGHT HEAD LAMP
1. When the plug is installed to the resin cover (4) hole, remove it.
2. Rotate the screws (1) (2 pieces) through the resin cover (4) hole
with the phillips-head screwdriver. Be sure to rotate them alter-
nately in the same direction by 1 turn (360°).
REMARK
q Turn the phillips-head screwdriver clockwise to move the op-
tical axis to the left side of the machine.
q Turn the phillips-head screwdriver counterclockwise to move
the optical axis to the right side of the machine.
q Rotate the screws (1) (2 pieces) with the same number of
turns to tighten them. If the number of turns is not the same, the screws (1) come off from the sockets (2) so that the
head lamps rattle.
q The maximum number of the turns must be six.
q If the screws are turned more than maximum, the screws (1) come off from the sockets (2) so that the head lamps rattle.
3. Make sure that the screws (1) do not come off from the sockets
(2).
REMARK
If the screws (1) come off from the sockets (2) as shown NG in
the figure, return the optical axes to the initial position referring to
“PROCEDURE TO RETURN OPTICAL AXES TO INITIAL POSI-
TIONS (DEFAULT)” below. Then repeat the procedures from
step 1 and make sure that they are in correct condition as shown
OK in the figure.
HD465-8, HD605-8 30-343

ADJUST OPTICAL AXIS OF HEAD LAMP 30 TEST AND ADJUST
PROCEDURE TO ADJUST LEFT AND RIGHT OPTICAL AXES OF LEFT HEAD LAMP
REMARK
tical axis to the right side of the machine.
the optical axis to the left side of the machine.
head lamps rattle.
(2).
REMARK
OK in the figure.
PROCEDURE TO ADJUST UPPER AND LOWER OPTICAL AXES OF RIGHT HEAD LAMP
REMARK
tical axis to the upper side of the machine.
the optical axis to the lower side of the machine.
head lamps rattle.
(2).
REMARK
OK in the figure.
30-344 HD465-8, HD605-8

30 TEST AND ADJUST ADJUST OPTICAL AXIS OF HEAD LAMP
PROCEDURE TO ADJUST UPPER AND LOWER OPTICAL AXES OF LEFT HEAD LAMP
REMARK
tical axis to the upper side of the machine.
the optical axis to the lower side of the machine.
head lamps rattle.
(2).
REMARK
OK in the figure.
PROCEDURE TO RETURN OPTICAL AXES TO INITIAL POSITIONS (DEFAULT)

1. If the screws (1) come off from the sockets (2) as shown NG in
the figure, hold the head lamp and put the screws (1) into the
sockets (2), place it in correct condition as shown OK in the
figure.
2. With the head lamp installed to the bracket (3), adjust the screws
(1) with the flat-head screwdriver from the rear side (H).
REMARK
Adjust the dimension (L) for all the screws (1) (4 pieces).
Head lamp (high beam): L = 19 mm
Head lamp (low beam): L = 23 mm
HD465-8, HD605-8 30-345

ENGINE CONTROLLER VOLTAGE CIRCUIT WORK 30 TEST AND ADJUST
ENGINE CONTROLLER VOLTAGE CIRCUIT WORK

NOTICE
q Disconnecting or connecting work of the connector between the engine controller and the engine must be per-
formed only when the start switch and battery disconnect switch are in OFF position.
q Before connecting the wiring harness connector, be sure to completely remove sand, dust, water, inside the con-
nector on the controller side.
q Even when you perform troubleshooting, do not start the engine while a T-adapter is inserted into or connected
to the connector between the engine controller and engine.
REMARK
You may turn the start switch to OFF or ON position but do not turn it to START position. (Do not start the engine.)
30-346 HD465-8, HD605-8

30 TEST AND ADJUST BATTERY DISCONNECT SWITCH WORK
BATTERY DISCONNECT SWITCH WORK

(O): OFF position
(I): ON position
q Battery disconnect switch (1) is usually used in the following cas-
es in the same purpose of disconnecting the cable from the neg-
ative terminal of the battery.
q When you store the machine for a long period (1 month or
longer)
q When you service or repair the electrical system
q When you perform electric welding
q When you handle the battery
q When you replace the fuse
q When battery disconnect switch (1) is at OFF position, all the
continuous power supplies for the components including the start
switch B terminal and controllers are all cut out. It is the same
state as the time when the battery is not connected. All of the
electrical system of the machine will not operate.
k If the battery disconnect switch (1) is turned to ON position
by unauthorized person, it is extremely dangerous.
q The controllers are protected from abnormal disconnection,
which shuts off the battery power supply circuit even when the
controllers are operating, by checking if the system operation
lamp (2) is lit to show that any of systems is in operation.
q Before shutting off the battery power supply circuit, turn the start
switch to OFF position, and check that system operation lamp (2)
goes out, then turn the battery disconnect switch (1) to OFF position.
q If battery disconnect switch (1) is turned to OFF position (the battery power supply circuit is shut off) while the system op-
eration lamp is lit, the controller data loss error may be shown. Never operate the battery disconnect switch (1) while the
system operating lamp (2) is lit.
q The system operating lamp (2) goes out in maximum. 3 minutes after the starting switch is turned to OFF position.
q Even if system operating lamp (2) is not lit, it may seem to be lit slightly because of a very little leakage current inside the
controller. This phenomenon does not indicate abnormality.
q System operation lamp (2) may sometimes light up while the start switch is turned to OFF position because the KOMTRAX
terminal repeats the start and stop to maintain the periodic communication.
q The start and stop cycle (sleep cycle) of KOMTRAX terminal varies depending on the factors including the communication
state and the time when the machine is not in operation, and the lamp may be lit approximately may be lit for a maximum
of approximately one hour.
q When you want to cut off the battery circuit for maintenance but system operating lamp (2) is kept lit, turn the starting switch
to ON position once, and then turn it to OFF position, and the lamp goes out in a maximum of 3 minutes. After the system
operating lamp (2) goes out, turn the battery disconnect switch (1) immediately to OFF position.
q Do not turn OFF battery disconnect switch (1) while the engine is running or immediately after the engine is stopped.
If battery disconnect switch (1) is turned OFF while the alternator is generating power, the generated current has nowhere
to go, leading to overvoltage in the electrical system of the machine, which may cause serious damage to the electrical
system, including the electric devices and controllers.
q If battery disconnect switch (1) is turned OFF for a long period, the machine monitor and the clock of the radio may be
initialized. In this case, adjustment is required.
q Do not turn the battery disconnect switch (1) to OFF position while the fan is rotating in reverse.
While the fan is rotating in reverse, even if the start switch is turned to OFF position, fan reverse solenoid is energized for
a while in order to protect the hydraulic motor.
Make sure that the fan stops completely before turning battery disconnect switch (1) to OFF position.
HD465-8, HD605-8 30-347

TEST DIODES 30 TEST AND ADJUST
TEST DIODES
Test the diode array (8-pin) and the single diode (2-pin) according to
the following procedure.
The continuity directions of the diode array are as shown in the fig-
ure.
REMARK
The continuity direction of the single diode is indicated on the surface
of the diode.
PROCEDURE TO TEST DIODE USING DIGITAL TESTER

1. Select the screen to the diode range to check the displayed
values.
REMARK
When an ordinary circuit multimeter is used, the voltage of the in-
ternal battery is indicated.
2. Apply the red (+) lead of the multimeter to the anode (P) side of
the diode and apply the black (-) lead to the cathode (N) side, and
check the indicated value.
3. Evaluate the condition of the diode by the indicated value.
Indicated value does not change: No continuity (defective)
Indicated value changes: Continuity (normal) (*)
*: In the case of a silicon diode, a value in the range between 460 to 600 mV.
PROCEDURE TO TEST DIODE USING ANALOG TESTER
1. Switch to the resistance range.
2. Apply the red (+) lead of the multimeter to the anode (P) side of the diode and apply the black (-) lead to the cathode (N)
side, and check the deflection of the pointer.
3. Apply the red (+) lead of the multimeter to the cathode (P) side of the diode and apply the black (-) lead to the anode (N)
side, and check the deflection of the pointer.
4. Evaluate the condition of the diode by the level of the pointer deflection.
The pointer deflection result

Judgment
Result of step 2 Result of step 3
Normal (Deflection degree (resistance)
Deflect Not deflect varies according to the tester types or
the measurement range selection)
Deflect Deflect Defective (Internal short circuit)
Not deflect Not deflect Defective (Internal wire disconnection)
30-348 HD465-8, HD605-8

30 TEST AND ADJUST Pm CLINIC SERVICE
Pm CLINIC
Pm CLINIC SERVICE
Machine model Serial No. Service meter Odometer
□ HD465-8 □ HD605-8 h km
User name Inspector Date of inspection
Specifications
□ Tire size
Operating condition
Quarry, mining Construction Type of soil Contents of operation
□ Construction, civil
□ Coal □ Rock □ Transportation %
engineering
□ Gold □ Gravel □ %
□ Road
□ Limestone □ Sand □ %
□ Tunnel
□ □ Clay □ %
□
Check of oil and coolant levels
□ Engine coolant When necessary

□ Engine oil level □ Damper case oil level □ Final drive oil level
□ Hydraulic oil level □ Power train oil level □
Ambient temperature Altitude
Max. ˚C
Min. ˚C m
Is engine coolant temperature normal during Is retarder oil temperature normal during
˚C ˚C
operation? operation?
Is torque converter oil temperature normal during
˚C
operation?
Operator's comment
Result of visual inspection
Failure Failure
Mechanical Sys Abnormality Record Electrical Sys Abnormality Record
code code
1500L0 Times/First time h/Latest h Times/First time h/Latest h
15B0NX Times/First time h/Latest h Times/First time h/Latest h
HD465-8, HD605-8 30-349

Pm CLINIC SERVICE 30 TEST AND ADJUST
Failure Failure
code code
15F0KM Times/First time h/Latest h Times/First time h/Latest h
15F0MB Times/First time h/Latest h Times/First time h/Latest h
15G7KM Times/First time h/Latest h Times/First time h/Latest h
2C4MNX Times/First time h/Latest h Times/First time h/Latest h
2G42ZG Times/First time h/Latest h Times/First time h/Latest h
2G43ZG Times/First time h/Latest h Times/First time h/Latest h
6014NX Times/First time h/Latest h Times/First time h/Latest h
989D00 Times/First time h/Latest h Times/First time h/Latest h
989X00 Times/First time h/Latest h Times/First time h/Latest h
989Y00 Times/First time h/Latest h Times/First time h/Latest h
A1U0N3 Times/First time h/Latest h Times/First time h/Latest h
A1U0N4 Times/First time h/Latest h Times/First time h/Latest h
AA10NX Times/First time h/Latest h Times/First time h/Latest h
AQ00N3 Times/First time h/Latest h Times/First time h/Latest h
B@BAZG Times/First time h/Latest h Times/First time h/Latest h
B@BAZK Times/First time h/Latest h Times/First time h/Latest h
B@BCNS Times/First time h/Latest h Times/First time h/Latest h
B@BCQA Times/First time h/Latest h Times/First time h/Latest h
B@BCZK Times/First time h/Latest h Times/First time h/Latest h
B@C7NS Times/First time h/Latest h Times/First time h/Latest h
B@CENS Times/First time h/Latest h Times/First time h/Latest h
B@JANS Times/First time h/Latest h Times/First time h/Latest h
CA234 Times/First time h/Latest h Times/First time h/Latest h
CB1921 Times/First time h/Latest h Times/First time h/Latest h
DAQV00 Times/First time h/Latest h Times/First time h/Latest h
DAQW00 Times/First time h/Latest h Times/First time h/Latest h
DHT8ZG Times/First time h/Latest h Times/First time h/Latest h
DY30ME Times/First time h/Latest h Times/First time h/Latest h
F@BYNR Times/First time h/Latest h Times/First time h/Latest h
30-350 HD465-8, HD605-8

Failure Failure
code code
F@BYNS Times/First time h/Latest h Times/First time h/Latest h
Max. range of engine coolant temperature gauge
Coolant
Engine coolant Color when monitor
temperature gauge
temperature lights up
level
A1 135 °C
Red
A2 102 °C
A3 88 °C
A4 74 °C Green
A5 59 °C
A6 50 °C White
Max. range of torque converter oil temperature gauge
Oil temperature Torque converter Color when monitor

level oil temperature lights up
B1 135 °C
Red
B2 120 °C
B3 97 °C
B4 73 °C Green
B5 50 °C
Max. range of retarder oil temperature gauge
Oil temperature Retarder oil Color when monitor

level temperature lights up
C1 50 °C
Red
C2 120 °C
C3 97 °C
C4 73 °C Green
C5 50 °C
HD465-8, HD605-8 30-351

Pm CLINIC CHECK SHEET: HD465-8

k The torque converter stall is performed at F2 gear speed, make sure to set the moving-off gear speed to "F2" in
"F1 Start at D Position Setting".
k Keep depressing the R.H. brake pedal fully for the torque converter stall.
NOTICE
Perform the checks after sufficient warm-up operation of the engine.
q Be careful of the increase in the torque converter oil temperature during a stall test. Do not allow the torque converter to
become too hot.

□ HD465-8 h km
Engine

Engine SAA6D170E-7
Standard
Measured No
Item Test conditions Unit value for new Repair limit Good
value good
machine
Engine speed at 2220 to 2220 to
q Torque converter oil temperature: 60 to 80 ˚C rpm
high idle (*1) 2320 2320
q Accelerator pedal: Depress to stroke end
(High idle)
q Engine coolant temperature: AISS LOW
rpm 700 to 800 700 to 800
65 to 100 ˚C switch: ON
q Steering oil temperature: 45 to
55 ˚C
Engine speed at
q Torque converter oil tempera-
low idle (*1) AISS LOW 1050 to 1050 to
ture: rpm
60 to 80 °C switch: OFF 1150 1150
q Accelerator pedal: Not de-
pressed (Low idle)
Engine speed
q Torque converter oil temperature: 70 to 80
with torque 1831 to 1831 to
˚C rpm
converter 2031 2031
stalled (*1)
30-352 HD465-8, HD605-8


Engine SAA6D170E-7
Standard
Measured No
value good
machine
q Engine coolant temperature: Min. 60 ˚C
q Engine oil (*2)
EO10W30-LA
EO15W45-LA MPa Min. 0.34 Min. 0.21
EOS5W30-LA {kg/cm2} {Min. 3.47} {Min. 2.14}
EOS5W40-LA
Engine oil (High idle)
pressure
q Engine oil (*2)
EO15W45-LA
EOS5W40-LA
Blowby q Torque converter oil temperature: 60 to 80 kPa {Max. 3.43} Max. 9.41
pressure ˚C {mmH2O} {Max. 350} {Max. 960}
kPa {Min. 267.3} Min. 250.3
Boost pressure q Torque converter oil temperature: 60 to 80 °C
{mmHg} {Min. 2005} {Min. 1878}
q Full speed range (ambient temperature: 20
˚C)
Exhaust q Engine coolant temperature: 60 to 100 ˚C
temperature q Steering oil temperature: 45 to 55 ˚C ˚C Max. 700 Max. 700
(*1) q Torque converter oil temperature: 60 to 80
˚C
*1: Item that can be checked in monitoring function of machine monitor.

Power train

Engine SAA6D170E-7
Standard
Measured No
value good
machine
3.33 to 3.33 to
Main relief ˚C MPa 3.73 3.73
pressure of q Transmission oil temperature: 70 to 90 ˚C
power train q Gear speed: N position {kg/cm2} {34.0 to {34.0 to
38.0} 38.0}
q Engine speed: 2000 rpm (Target value)
Torque ˚C MPa 0.71 to 0.71 to
converter inlet q Transmission oil temperature: 70 to 90 ˚C 0.91 0.91
pressure q Gear shift lever: N position {kg/cm2} {7.3 to 9.3} {7.3 to 9.3}
HD465-8, HD605-8 30-353


Engine SAA6D170E-7
Standard
Measured No
value good
machine
converter outlet q Transmission oil temperature: 70 to 90 ˚C 2 0.69 0.69
pressure q Gear shift lever: N position {kg/cm } {5.0 to 7.0} {5.0 to 7.0}
Torque q Torque converter oil temperature: 60 to 100
1.71 to 1.71 to
converter ˚C MPa 2.11 2.11
lockup clutch q Transmission oil temperature: 70 to 90 ˚C 2
{kg/cm } {17.5 to {17.5 to
operating q Gear shift lever: L position
21.5} 21.5}
pressure q Engine speed: 2000 rpm (Target value)
Transmission

Engine SAA6D170E-7
Standard
Measured No
value good
machine
Metallic Metallic
powder and powder and
disc disc
Transmission abrasion abrasion
Visual inspection -
strainer powder are powder are
not not
incorporated incorporated
excessively excessively
Steering

Engine SAA6D170E-7
Standard
Measured No
value good
machine
Engine
speed: 750
q Steering cylinder left (right) rpm (Target
travel end - right (left) travel value)
Operating time end Engine
q Operating speed: 60 rpm speed:
q Dump body: Unloaded 2000 rpm Sec. Max. 3.6 Max. 3.6
(Target
value)
19.62 to 19.62 to
Steering circuit q Steering and hoist pump: Swash plate angle MPa 21.58 21.58
relief pressure maximum fixing (adjustment menu) 2 {200 to {200 to
(*1) q Accelerator pedal: Depress to stroke end {kg/cm }
220} 220}
(High idle)
30-354 HD465-8, HD605-8

Brake

Engine SAA6D170E-7
Standard
Measured No
value good
machine
16.4 to 16.4 to
Front wheel MPa 18.8 18.8
brake operating
pressure {kg/cm2} {168 to {168 to
192} 192}
Rear wheel Actuating pressure in the 1st operation after MPa 9.11 to 9.11 to
brake operating charging the accumulator and stopping the 10.49 10.49
pressure engine {kg/cm2} {93 to 107} {93 to 107}
8.06 to 8.06 to
Retarder brake MPa 9.34 9.34
operating
pressure {kg/cm2} {82.0 to {82.0 to
95.0} 95.0}
Cut-in pressure 13.22 to 13.22 to
of accumulator MPa 15.18 15.18
charge valve {kg/cm2} {135 to {135 to
(*1) q Steering oil temperature: 45 to 55 ˚C 150} 150}
Cut-out q Accelerator pedal: Depress to stroke end
(High idle) 19.13 to 19.13 to
pressure of MPa 21.58 21.58
accumulator
220} 220}
(*1)
q Condition of travel ground: Flat (Concrete
road surface) Machine Machine
q Dump body: Unloaded does not does not
Foot brake
q Brake pedal: Depress to travel end move at move at
braking -
q Gear shift lever: D position (Shift indicator engine engine
performance
shows F2) speed speed
q Stall the torque converter with the engine at 1810 rpm. 1810 rpm.
standard speed
road surface)
Machine Machine
q Dump body: Unloaded
does not does not
Retarder brake q Retarder control lever: Pull fully toward this
move at move at
braking side -
engine engine
performance q Gear shift lever: D position (Shift indicator
speed speed
shows F2)
1400 rpm. 1400 rpm.
q Stall the torque converter with the engine at
standard speed
Parking brake q Parking brake switch: Parking (P) position move at move at
-
performance q Gear shift lever: D position (Shift indicator engine engine
standard speed
HD465-8, HD605-8 30-355

Engine SAA6D170E-7
Standard
Measured No
value good
machine
road surface)
Machine Machine
does not does not
Secondary q Secondary brake pedal: Depress to travel
move at move at
brake braking end -
engine engine
speed speed
shows F2)
1670 rpm. 1670 rpm.
standard speed
Wear of front Brake pad thickness from the Left

mm 19.5 3
brake pad present position to the wear limit Right
Left Must be Must be
q Brake pedal: Depress to travel within within
Wear of rear
end - range of range of
brake disc
q Measure with disc wear gauge Right disc wear disc wear
gauge gauge

Dump body

Engine SAA6D170E-7
Standard
Measured No
value good
machine
q Steering oil temperature: 45 to 55 ˚C 19.62 to 19.62 to
Hoist circuit q Dump lever: Up MPa 21.58 21.58
relief pressure q Accelerator pedal: Depress to stroke end {kg/cm2} {200 to {200 to
(High idle) 220} 220}
q Steering oil temperature: 45 to 55 ˚C MPa
Hoist EPC valve 3.2 to 3.6 3.2 to 3.6
supply pressure
(High idle) {kg/cm2} {33 to 37} {33 to 37}

Dump body 10.0 to 10.0 to
q Dump lever: Up Sec.
raise time 13.0 13.0
q Dump lever: Float Sec.
lower time 13.0 13.0
The shrinkage amount of No. 2 cylinder 5
minutes after the engine is stopped when the
Hydraulic drift mm Max. 85 Max. 170
extension point of No. 2 cylinder (rod) is about
100 mm
Axle

Engine SAA6D170E-7
Standard
Measured No
value good
machine
No No
Differential case q Engine: Stopped excessive excessive
-
drain plug q Visual inspection metallic metallic
powder powder
Left No No
Final drive case q Engine: Stopped excessive excessive
-
drain plug q Visual inspection Right metallic metallic
powder powder
Suspension

Engine SAA6D170E-7
Standard
Measured No
value good
machine
Left front Installed length mm 245 to 265 235 to 275
suspension
cylinder Presence or absence of oil and gas leakage - No leakage No leakage
Right front Installed length mm 245 to 265 235 to 275

suspension
Left rear Installed length mm 194 to 214 184 to 224

suspension
Right rear Installed length mm 194 to 214 184 to 224

suspension
Hitting of rear Left - No hitting No hitting

suspension
stopper Right - No hitting No hitting
HD465-8, HD605-8 30-357

Pm CLINIC CHECK SHEET: HD605-8

k The torque converter stall is performed at F2 gear speed, make sure to set the moving-off gear speed to "F2" in
"F1 Start at D Position Setting".
k Keep depressing the R.H. brake pedal fully for the torque converter stall.
NOTICE
Perform the checks after sufficient warm-up operation of the engine.
q Be careful of the increase in the torque converter oil temperature during a stall test. Do not allow the torque converter to
become too hot.

□ HD605-8 h km
Engine

Engine SAA6D170E-7
Standard
Measured No
value good
machine
Engine speed at 2220 to 2220 to
q Torque converter oil temperature: 60 to 80 °C rpm
high idle (*1) 2320 2320
(High idle)
q Engine coolant temperature: AISS LOW
rpm 700 to 800 700 to 800
65 to 100 ˚C switch: ON
q Steering oil temperature: 45 to
55 ˚C
Engine speed at
q Torque converter oil tempera-
low idle (*1) AISS LOW 1050 to 1050 to
ture: rpm
60 to 80 °C switch: OFF 1150 1150
q Accelerator pedal: Not de-
pressed (Low idle)
Engine speed
with torque 1831 to 1831 to
˚C rpm
converter 2031 2031
stalled (*1)
30-358 HD465-8, HD605-8


Engine SAA6D170E-7
Standard
Measured No
value good
machine
q Engine oil (*2)
EO10W30-LA
EOS5W40-LA
Engine oil (High idle)
pressure
q Engine oil (*2)
EO15W45-LA
EOS5W40-LA
Blowby q Torque converter oil temperature: 60 to 80 kPa {Max. 3.43} Max. 9.41
pressure ˚C {mmH2O} {Max. 350} {Max. 960}
kPa {Min. 267.3} Min. 250.3
Boost pressure q Torque converter oil temperature: 60 to 80 °C
{mmHg} {Min. 2005} {Min. 1878}
q Full speed range (ambient temperature: 20
˚C)
Exhaust q Engine coolant temperature: 60 to 100 ˚C
temperature q Steering oil temperature: 45 to 55 ˚C ˚C Max. 700 Max. 700
(*1) q Torque converter oil temperature: 60 to 80
˚C

Power train

Engine SAA6D170E-7
Standard
Measured No
value good
machine
3.33 to 3.33 to
Main relief ˚C MPa 3.73 3.73
pressure of q Transmission oil temperature: 70 to 90 ˚C
power train q Gear speed: N position {kg/cm2} {34.0 to {34.0 to
38.0} 38.0}
converter inlet q Transmission oil temperature: 70 to 90 ˚C 0.91 0.91
pressure q Gear shift lever: N position {kg/cm2} {7.3 to 9.3} {7.3 to 9.3}
HD465-8, HD605-8 30-359


Engine SAA6D170E-7
Standard
Measured No
value good
machine
converter outlet q Transmission oil temperature: 70 to 90 °C 2 0.69 0.69
pressure q Gear shift lever: N position {kg/cm } {5.0 to 7.0} {5.0 to 7.0}
Torque q Torque converter oil temperature: 60 to 100
1.71 to 1.71 to
converter ˚C MPa 2.11 2.11
lockup clutch q Transmission oil temperature: 70 to 90 ˚C 2
{kg/cm } {17.5 to {17.5 to
operating q Gear shift lever: L position
21.5} 21.5}
pressure q Engine speed: 2000 rpm (Target value)
Transmission

Engine SAA6D170E-7
Standard
Measured No
value good
machine
Metallic Metallic
powder and powder and
disc disc
Transmission abrasion abrasion
Visual inspection -
strainer powder are powder are
not not
incorporated incorporated
excessively excessively
Steering

Engine SAA6D170E-7
Standard
Measured No
value good
machine
Engine
speed: 750
q Steering cylinder left (right) rpm (Target
travel end - right (left) travel value)
Operating time end Engine
q Operating speed: 60 rpm speed:
q Dump body: Unloaded 2000 rpm Sec. Max. 3.6 Max. 3.6
(Target
value)
19.62 to 19.62 to
Steering circuit q Steering and hoist pump: Swash plate angle MPa 21.58 21.58
relief pressure maximum fixing (adjustment menu) 2 {200 to {200 to
(*1) q Accelerator pedal: Depress to stroke end {kg/cm }
220} 220}
(High idle)
30-360 HD465-8, HD605-8

Brake

Engine SAA6D170E-7
Standard
Measured No
value good
machine
Front wheel MPa 16.4 to 18.8 16.4 to 18.8
brake operating
pressure {kg/cm2} {168 to 192} {168 to 192}
Rear wheel MPa 9.11 to 9.11 to

Actuating pressure in the 1st operation after
brake operating 2 10.49 10.49
charging the accumulator and stopping the {kg/cm } {93 to 107} {93 to 107}
pressure
engine
8.06 to 8.06 to
Retarder brake MPa 9.34 9.34
operating
pressure {kg/cm2} {82.0 to {82.0 to
95.0} 95.0}
Cut-in pressure 13.22 to 13.22 to
of accumulator MPa 15.18 15.18
(*1) q Steering oil temperature: 45 to 55 ˚C 150} 150}
Cut-out q Accelerator pedal: Depress to stroke end
(High idle) 19.13 to 19.13 to
pressure of MPa 21.58 21.58
accumulator
220} 220}
(*1)
Foot brake
q Brake pedal: Depress to travel end move at move at
braking -
q Gear shift lever: D position (Shift indicator engine engine
performance
standard speed
road surface)
Machine Machine
does not does not
Retarder brake q Retarder control lever: Pull fully toward this
move at move at
braking side -
engine engine
speed speed
shows F2)
1400 rpm. 1400 rpm.
standard speed
Parking brake q Parking brake switch: Parking (P) position move at move at
-
performance q Gear shift lever: D position (Shift indicator engine engine
standard speed
HD465-8, HD605-8 30-361


Engine SAA6D170E-7
Standard
Measured No
value good
machine
road surface)
Machine Machine
does not does not
Secondary q Secondary brake pedal: Depress to travel
move at move at
brake braking end -
engine engine
speed speed
shows F2)
1670 rpm. 1670 rpm.
standard speed
Wear of front Brake pad thickness from the Left

mm 19.5 3
brake pad present position to the wear limit Right
Left Must be Must be
q Brake pedal: Depress to travel within within
Wear of rear
end - range of range of
brake disc
q Measure with disc wear gauge Right disc wear disc wear
gauge gauge

Dump body

Engine SAA6D170E-7
Standard
Measured No
value good
machine
q Steering oil temperature: 45 to 55 ˚C 19.62 to 19.62 to
Hoist circuit q Dump lever: Up MPa 21.58 21.58
relief pressure q Accelerator pedal: Depress to stroke end {kg/cm2} {200 to {200 to
(High idle) 220} 220}
q Steering oil temperature: 45 to 55 ˚C MPa
Hoist EPC valve 3.2 to 3.6 3.2 to 3.6
supply pressure
(High idle) {kg/cm2} {33 to 37} {33 to 37}

q Dump lever: Up Sec.
raise time 13.0 13.0
q Dump lever: Float Sec.
lower time 13.0 13.0
The shrinkage amount of No. 2 cylinder 5
minutes after the engine is stopped when the
Hydraulic drift mm Max. 85 Max. 170
extension point of No. 2 cylinder (rod) is about
100 mm
30-362 HD465-8, HD605-8

Axle

Engine SAA6D170E-7
Standard
Measured No
value good
machine
No No
Differential case q Engine: Stopped excessive excessive
-
drain plug q Visual inspection metallic metallic
powder powder
Left No No
Final drive case q Engine: Stopped excessive excessive
-
drain plug q Visual inspection Right metallic metallic
powder powder
Suspension

Engine SAA6D170E-7
Standard
Measured No
value good
machine
Left front Installed length mm 245 to 265 235 to 275
suspension
Right front Installed length mm 245 to 265 235 to 275

suspension
Left rear Installed length mm 194 to 214 184 to 224

suspension
Right rear Installed length mm 194 to 214 184 to 224

suspension
Hitting of rear Left - No hitting No hitting

suspension
stopper Right - No hitting No hitting
HD465-8, HD605-8 30-363

PERFORMING QUICK Pm 30 TEST AND ADJUST
PERFORMING QUICK Pm
Quick Pm is the Pm clinic performed by using the "Manual Snap Shot" function of the machine monitor. Data of 7 minutes and
30 seconds is recorded in the KOMTRAX Plus controller. When you collect the data periodically, the operation must obey the
instructions given in Quick pm.
REMARK
q The data recorded in the KOMTRAX Plus controller are recorded with Manual Snap Shot and the data recorded automat-
ically when the specified error occurs. The data is recorded a maximum of 9 times.
q When the data of maximum number of times are recorded in the KOMTRAX Plus controller, data will not record when Man-
ual Snap Shot is performed.
q Before Manual Snap Shot is performed, download the data recorded in the KOMTRAX Plus controller to the PC and delete
the data in the KOMTRAX Plus controller.
q To use the data recorded with Manual Snap Shot, load the data to a personal computer.
PROCEDURE TO PERFORM QUICK Pm
1. See "DOWNLOAD OF KOMTRAX Plus CONTROLLER DATA"
to download the data recorded in the KOMTRAX Plus controller
to the PC.
REMARK
After downloading the data to the PC, delete the data in the
KOMTRAX Plus controller.
3. Select "Manual Snap Shot" from the "Service Menu" screen.

4. "Manual Snap Shot" screen is shown. Make sure that the oil
temperature and coolant temperature are in the range of the test
condition, and push UP switch (10).
UP switch (10): Proceeds to the confirmation screen to start
recording
30-364 HD465-8, HD605-8

30 TEST AND ADJUST PERFORMING QUICK Pm
5. When "Start Snapshot?" is shown, push the ENTER switch (13).

RETURN switch (12): Stops recording, and returns to the
ENTER switch (13): Starts to record
6. Starts to record data. Operate the machine, refer to "Operation

table of machine in Quick Pm".
DOWN switch (11): Proceed to the confirmation screen to stop
Manual Snap Shot or not.
REMARK
q Examine the progress recorded on the machine monitor. For
progress of recording, see "PROCEDURE FOR MANUAL
SNAP SHOT".
q To cancel Manual Snap Shot, push DOWN switch (11).

When "Stop Snapshot?" is shown, push ENTER switch. The
display returns to the screen of step 4.
HD465-8, HD605-8 30-365

Operation table of machine in Quick Pm

Operation of machine
Operating Parking Retarder
No. Start End time AISS Gear shift Dump
Operation Accelerat Brake brake control
(Sec.) LOW lever lever
status or pedal pedal switch lever
switch position position
position position
OFF
Low idle
1 0:00 2:00 120 (Automati - - N Parking Pull Keep
(Low)
c control)
Depress
Low idle
2 2:00 3:00 60 ↑ - (Continue ↑ Travel Return Keep
(High)
)
3 3:00 3:30 30 High idle ↑ Depress - ↑ Parking Pull Up (*1)
4 3:30 4:00 30 High idle ↑ ↑ - ↑ ↑ ↑ Keep (*1)
Low idle
5 4:00 5:00 60 ↑ - - ↑ ↑ ↑ Float
(Low)
6 5:00 5:30 30 High idle ↑ Depress - ↑ ↑ ↑ Keep
Torque
30
7 5:30 6:00 converter ↑ ↑(*3) - D (*3) ↑ ↑ ↑
(*2)
stalled
8 6:00 6:30 30 High idle ↑ ↑ - N ↑ ↑ ↑
Torque
30
9 6:30 7:00 converter ↑ ↑(*3) - D (*3) ↑ ↑ ↑
(*2)
stalled
Depress
10 7:00 7:30 30 High idle ↑ ↑ (Repeat N ↑ ↑ ↑
20 times)
*1: If the dump body is not able to be lifted up in a maintenance garage, perform No. 5 (alternative to No. 3 and No. 4) for 120
seconds.
*2: 30 seconds is an estimate. If the torque converter is too hot, lift your right foot off the accelerator pedal, and set the gear
shift lever to N.
*3: Lift your foot off the accelerator pedal and set the engine speed at low idle, then set the gear shift lever to D.
NOTICE
Be careful of the increase in the torque converter oil temperature during a stall test. Do not allow the torque converter
to become too hot.
REMARK
q AISS LOW switch operation is not necessary.
q When you operate the accelerator pedal, brake pedal, or retarder control lever, operate the pedals and lever to their full
travel.
q The torque converter stall is performed at F2 gear speed, make sure to set the moving-off gear speed to "F2" in "F1 Start
at D Position Setting".
q For details of stalling torque converter, see "TEST ENGINE SPEED", "Procedure to test engine speed at torque converter
stall".
30-366 HD465-8, HD605-8

30 TEST AND ADJUST PERFORMING QUICK Pm
q If "Snapshot is completed." is shown after 7 minutes and 30 sec-

onds from the record start, the data record is completed.
q 3 seconds after the record function completes, the screen goes
back to "Manual Snap Shot".
Load the recorded data to a personal computer, and use the data for find malfunctions of the machine.
REMARK
q To download data, see "DOWNLOAD OF KOMTRAX Plus CONTROLLER DATA".
q The data of "Manual Snap Shot" is recorded in the KOMTRAX Plus controller only one time. The data is written over when
"Manual Snap Shot" is performed continuously. Make sure to download the data to the PC after you perform "Manual Snap
Shot".
HD465-8, HD605-8 30-367

30-368 HD465-8, HD605-8

40 TROUBLESHOOTING
HD465-8, HD605-8 40-1

CONTENTS 40 TROUBLESHOOTING
CONTENTS
ABBREVIATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-16
RELATED INFORMATION ON TROUBLESHOOTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-21
GENERAL TROUBLESHOOTING POINTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-21
TROUBLESHOOTING POINTS FOR AFTERTREATMENT SYSTEMS - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-22
SEQUENCE OF EVENTS IN TROUBLESHOOTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-28
CHECKS BEFORE TROUBLESHOOTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-30
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-33
WALK-AROUND CHECK- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-33
TESTING IN ACCORDANCE WITH TESTING PROCEDURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-34
CHECK FUEL LEVEL AND TYPE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-34
CHECK IMPURE INGREDIENT IN FUEL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-34
CHECK FUEL PREFILTER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-34
CHECK MAIN FILTER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-36
OIL PAN - CHECK ENGINE OIL LEVEL AND TYPE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-38
CHECK COOLANT LEVEL (RESERVOIR TANK)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-38
CHECK CLOGGING OF AIR CLEANER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-40
OUTER ELEMENT - CLEAN - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-41
REPLACE ELEMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-43
CHECK HYDRAULIC OIL LEVEL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-44
CHECK HYDRAULIC OIL STRAINER- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-44
CHECK HYDRAULIC FILTER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-45
CHECK OIL LEVEL IN TRANSMISSION CASE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-46
CHECK OIL LEVEL IN DIFFERENTIAL CASE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-46
CHECK OIL LEVEL IN FINAL DRIVE CASE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-46
BLEED AIR FROM FUEL SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-46
BLEED AIR FROM HYDRAULIC SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-47
METHOD FOR CHECKING ELECTRIC EQUIPMENT METHOD- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-47
ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-53
PROCEDURE FOR TESTING AND TROUBLESHOOTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-64
SYMPTOM AND TROUBLESHOOTING NUMBERS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-66
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-70
CONNECTORS LIST AND LAYOUT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-73
CONNECTOR CONTACT IDENTIFICATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-101
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-141
FUSE LOCATION TABLE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-147
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) - - - - - - - - - - - - - - - - - - - - - 40-153
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-157
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT - - - - - - - - - - 40-159
PREPARATION OF SHORT SOCKET ADAPTER (FOR FAILURE CODES [CA1883], [CB1883], [CA3135], AND
[CB3135]) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-165
FAILURE CODES TABLE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-167
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-192
FAILURE CODE [1500L0] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-192
FAILURE CODE [15B0NX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-193
FAILURE CODE [15F0KM] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-195
FAILURE CODE [15F0MB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-196
FAILURE CODE [15F7KM] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-197
FAILURE CODE [15G0MW] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-198
FAILURE CODE [15G7KM] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-199
40-2 HD465-8, HD605-8

40 TROUBLESHOOTING CONTENTS
FAILURE CODE [15H0MW] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-200

FAILURE CODE [15J0MW] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-201
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] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-214
FAILURE CODE [15SCMA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-217
FAILURE CODE [15SDL1] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-218
FAILURE CODE [15SDMA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-221
FAILURE CODE [15SEL1] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-222
FAILURE CODE [15SEMA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-225
FAILURE CODE [15SFL1] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-226
FAILURE CODE [15SFMA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-229
FAILURE CODE [15SGL1]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-230
FAILURE CODE [15SGMA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-233
FAILURE CODE [15SHL1] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-234
FAILURE CODE [15SHMA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-237
FAILURE CODE [15SJMA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-238
FAILURE CODE [2C4MNX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-239
FAILURE CODE [2F00KM] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-240
FAILURE CODE [2G42ZG] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-243
FAILURE CODE [2G43ZG] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-244
FAILURE CODE [6014NX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-245
FAILURE CODE [879AKA]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-246
FAILURE CODE [879AKB]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-247
FAILURE CODE [879BKA]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-248
FAILURE CODE [879BKB]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-249
FAILURE CODE [879CKA]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-251
FAILURE CODE [879CKB]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-252
FAILURE CODE [879EMC] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-253
FAILURE CODE [879FMC] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-254
FAILURE CODE [879GKX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-255
FAILURE CODE [989D00] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-256
FAILURE CODE [989L00] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-257
FAILURE CODE [989M00] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-258
FAILURE CODE [989N00] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-259
FAILURE CODE [989X00] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-260
FAILURE CODE [989Y00] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-261
FAILURE CODE [A1U0N3] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-262
FAILURE CODE [A1U0N4] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-263
FAILURE CODE [AA10NX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-265
FAILURE CODE [AB00KE] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-267
FAILURE CODE [AB00KY] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-269
FAILURE CODE [AQ00N3] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-270
FAILURE CODE [AQ00N4] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-271
FAILURE CODE [AQ10N3] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-272
FAILURE CODE [B@BAZG] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-273
HD465-8, HD605-8 40-3

FAILURE CODE [B@BAZK] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-274

FAILURE CODE [B@BCNS] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-275
FAILURE CODE [B@BCQA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-276
FAILURE CODE [B@BCZK] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-278
FAILURE CODE [B@C7NS] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-280
FAILURE CODE [B@CENS] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-282
FAILURE CODE [B@JANS] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-283
FAILURE CODE [CA115] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-284
FAILURE CODE [CA122] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-288
FAILURE CODE [CA123] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-290
FAILURE CODE [CA131] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-292
FAILURE CODE [CA132] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-294
FAILURE CODE [CA135] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-296
FAILURE CODE [CA141] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-298
FAILURE CODE [CA144] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-300
FAILURE CODE [CA145] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-302
FAILURE CODE [CA153] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-304
FAILURE CODE [CA154] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-306
FAILURE CODE [CA187] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-308
FAILURE CODE [CA212] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-310
FAILURE CODE [CA213] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-312
FAILURE CODE [CA221] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-314
FAILURE CODE [CA222] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-316
FAILURE CODE [CA227] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-318
FAILURE CODE [CA234] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-320
FAILURE CODE [CA238] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-321
FAILURE CODE [CA239] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-322
FAILURE CODE [CA271] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-323
FAILURE CODE [CA272] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-325
FAILURE CODE [CA273] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-326
FAILURE CODE [CA274] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-328
FAILURE CODE [CA322] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-329
FAILURE CODE [CA323] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-331
FAILURE CODE [CA324] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-333
FAILURE CODE [CA325] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-335
FAILURE CODE [CA331] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-337
FAILURE CODE [CA332] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-339
FAILURE CODE [CA343] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-341
FAILURE CODE [CA351] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-344
FAILURE CODE [CA352] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-347
FAILURE CODE [CA356] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-349
FAILURE CODE [CA357] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-351
FAILURE CODE [CA386] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-353
FAILURE CODE [CA431] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-355
FAILURE CODE [CA432] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-358
FAILURE CODE [CA441] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-361
FAILURE CODE [CA442] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-364
FAILURE CODE [CA449] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-367
FAILURE CODE [CA451] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-368
FAILURE CODE [CA452] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-370
40-4 HD465-8, HD605-8

FAILURE CODE [CA515]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-372

FAILURE CODE [CA516]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-374
FAILURE CODE [CA553]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-376
FAILURE CODE [CA555]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-377
FAILURE CODE [CA556]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-379
FAILURE CODE [CA559]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-381
FAILURE CODE [CA595]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-386
FAILURE CODE [CA687]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-388
FAILURE CODE [CA689]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-390
FAILURE CODE [CA691]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-392
FAILURE CODE [CA692]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-394
FAILURE CODE [CA697]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-396
FAILURE CODE [CA698]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-397
FAILURE CODE [CA731]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-398
FAILURE CODE [CA778]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-401
FAILURE CODE [CA1117] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-403
FAILURE CODE [CA1135] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-406
FAILURE CODE [CA1257] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-409
FAILURE CODE [CA1664] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-410
FAILURE CODE [CA1691] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-412
FAILURE CODE [CA1695] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-414
FAILURE CODE [CA1696] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-416
FAILURE CODE [CA1843] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-418
FAILURE CODE [CA1844] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-420
FAILURE CODE [CA1879] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-422
FAILURE CODE [CA1881] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-424
FAILURE CODE [CA1883] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-426
FAILURE CODE [CA1921] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-429
FAILURE CODE [CA1922] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-431
FAILURE CODE [CA1923] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-434
FAILURE CODE [CA1924] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-436
FAILURE CODE [CA1925] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-438
FAILURE CODE [CA1927] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-440
FAILURE CODE [CA1928] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-442
FAILURE CODE [CA1942] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-444
FAILURE CODE [CA1963] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-446
FAILURE CODE [CA1977] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-450
FAILURE CODE [CA1993] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-452
FAILURE CODE [CA2185] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-454
FAILURE CODE [CA2186] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-456
FAILURE CODE [CA2249] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-458
FAILURE CODE [CA2265] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-463
FAILURE CODE [CA2266] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-465
FAILURE CODE [CA2271] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-467
FAILURE CODE [CA2272] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-469
FAILURE CODE [CA2349] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-471
FAILURE CODE [CA2353] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-473
FAILURE CODE [CA2357] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-475
FAILURE CODE [CA2381] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-477
FAILURE CODE [CA2382] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-479
HD465-8, HD605-8 40-5

FAILURE CODE [CA2383] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-481

FAILURE CODE [CA2386] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-483
FAILURE CODE [CA2387] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-485
FAILURE CODE [CA2555] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-487
FAILURE CODE [CA2556] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-489
FAILURE CODE [CA2637] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-491
FAILURE CODE [CA2639] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-493
FAILURE CODE [CA2732] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-495
FAILURE CODE [CA2733] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-497
FAILURE CODE [CA2741] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-499
FAILURE CODE [CA2765] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-500
FAILURE CODE [CA2777] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-501
FAILURE CODE [CA2878] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-502
FAILURE CODE [CA2881] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-504
FAILURE CODE [CA3133] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-507
FAILURE CODE [CA3134] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-509
FAILURE CODE [CA3135] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-511
FAILURE CODE [CA3167] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-514
FAILURE CODE [CA3251] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-516
FAILURE CODE [CA3253] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-518
FAILURE CODE [CA3254] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-521
FAILURE CODE [CA3255] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-523
FAILURE CODE [CA3256] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-525
FAILURE CODE [CA3311] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-527
FAILURE CODE [CA3312] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-529
FAILURE CODE [CA3313] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-531
FAILURE CODE [CA3314] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-532
FAILURE CODE [CA3315] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-533
FAILURE CODE [CA3316] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-536
FAILURE CODE [CA3317] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-537
FAILURE CODE [CA3318] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-538
FAILURE CODE [CA3319] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-541
FAILURE CODE [CA3321] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-542
FAILURE CODE [CA3322] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-543
FAILURE CODE [CA3419] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-546
FAILURE CODE [CA3421] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-548
FAILURE CODE [CA4151] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-550
FAILURE CODE [CA4158] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-553
FAILURE CODE [CA4161] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-555
FAILURE CODE [CA4162] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-557
FAILURE CODE [CA4163] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-559
FAILURE CODE [CA4259] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-561
FAILURE CODE [CA4952] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-563
FAILURE CODE [CA5383] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-566
FAILURE CODE [CB115] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-567
FAILURE CODE [CB187] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-571
FAILURE CODE [CB227] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-572
FAILURE CODE [CB238] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-573
FAILURE CODE [CB239] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-575
FAILURE CODE [CB271] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-576
40-6 HD465-8, HD605-8

FAILURE CODE [CB272]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-578

FAILURE CODE [CB273]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-579
FAILURE CODE [CB274]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-581
FAILURE CODE [CB343]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-582
FAILURE CODE [CB352]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-585
FAILURE CODE [CB386]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-587
FAILURE CODE [CB441]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-589
FAILURE CODE [CB442]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-592
FAILURE CODE [CB689]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-595
FAILURE CODE [CB697]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-597
FAILURE CODE [CB698]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-598
FAILURE CODE [CB731]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-599
FAILURE CODE [CB778]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-602
FAILURE CODE [CB1117] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-604
FAILURE CODE [CB1257] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-607
FAILURE CODE [CB1664] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-608
FAILURE CODE [CB1691] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-610
FAILURE CODE [CB1695] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-612
FAILURE CODE [CB1696] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-614
FAILURE CODE [CB1879] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-616
FAILURE CODE [CB1881] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-618
FAILURE CODE [CB1883] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-620
FAILURE CODE [CB1921] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-623
FAILURE CODE [CB1922] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-625
FAILURE CODE [CB1923] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-628
FAILURE CODE [CB1924] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-630
FAILURE CODE [CB1925] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-632
FAILURE CODE [CB1927] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-634
FAILURE CODE [CB1928] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-636
FAILURE CODE [CB1963] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-638
FAILURE CODE [CB1977] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-642
FAILURE CODE [CB1993] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-644
FAILURE CODE [CB2265] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-646
FAILURE CODE [CB2266] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-648
FAILURE CODE [CB2637] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-650
FAILURE CODE [CB2639] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-652
FAILURE CODE [CB2732] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-654
FAILURE CODE [CB2733] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-656
FAILURE CODE [CB2741] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-658
FAILURE CODE [CB2777] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-659
FAILURE CODE [CB2878] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-660
FAILURE CODE [CB2881] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-662
FAILURE CODE [CB3133] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-665
FAILURE CODE [CB3134] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-667
FAILURE CODE [CB3135] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-669
FAILURE CODE [CB3167] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-672
FAILURE CODE [CB3251] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-674
FAILURE CODE [CB3253] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-676
FAILURE CODE [CB3254] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-679
FAILURE CODE [CB3255] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-681
HD465-8, HD605-8 40-7

FAILURE CODE [CB3256] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-683

FAILURE CODE [CB3311] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-685
FAILURE CODE [CB3312] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-687
FAILURE CODE [CB3313] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-689
FAILURE CODE [CB3314] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-690
FAILURE CODE [CB3315] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-691
FAILURE CODE [CB3316] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-694
FAILURE CODE [CB3317] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-695
FAILURE CODE [CB3318] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-696
FAILURE CODE [CB3319] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-699
FAILURE CODE [CB3321] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-700
FAILURE CODE [CB3322] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-701
FAILURE CODE [CB4151] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-704
FAILURE CODE [CB4158] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-707
FAILURE CODE [CB4161] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-708
FAILURE CODE [CB4162] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-710
FAILURE CODE [CB4163] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-712
FAILURE CODE [CB4259] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-714
FAILURE CODE [CB4952] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-716
FAILURE CODE [CB5383] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-719
FAILURE CODE [D150KB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-720
FAILURE CODE [D150KZ] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-721
FAILURE CODE [D164KY] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-722
FAILURE CODE [D19HKZ] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-723
FAILURE CODE [D19JKZ] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-725
FAILURE CODE [D19QKZ] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-726
FAILURE CODE [D1EHKA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-728
FAILURE CODE [D1EHKB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-730
FAILURE CODE [D1EHKY] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-732
FAILURE CODE [D1EMKA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-733
FAILURE CODE [D1EMKB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-734
FAILURE CODE [D1EMKY] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-735
FAILURE CODE [D1FBKB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-736
FAILURE CODE [D5ZHL6] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-738
FAILURE CODE [D5ZKKZ] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-740
FAILURE CODE [D862KA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-742
FAILURE CODE [DAF0KT] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-743
FAILURE CODE [DAF0MB]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-744
FAILURE CODE [DAF0MC] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-745
FAILURE CODE [DAF3KK] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-746
FAILURE CODE [DAF8KB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-748
FAILURE CODE [DAFDKB]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-749
FAILURE CODE [DAFGMC] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-751
FAILURE CODE [DAFLKA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-752
FAILURE CODE [DAFLKB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-755
FAILURE CODE [DAFQKR] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-758
FAILURE CODE [DAQ0KK]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-759
FAILURE CODE [DAQ0KT] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-762
FAILURE CODE [DAQ0MC] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-763
FAILURE CODE [DAQ1KA]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-764
40-8 HD465-8, HD605-8


FAILURE CODE [DAQ9KQ] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-770
FAILURE CODE [DAQLKA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-771
FAILURE CODE [DAQLKB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-774
FAILURE CODE [DAQQKR]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-777
FAILURE CODE [DAQRKR]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-778
FAILURE CODE [DAQRMA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-779
FAILURE CODE [DAQV00] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-780
FAILURE CODE [DAQW00] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-781
FAILURE CODE [DAZ9KQ] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-782
FAILURE CODE [DAZQKR] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-783
FAILURE CODE [DB10KT] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-784
FAILURE CODE [DB10MC] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-785
FAILURE CODE [DB11KA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-786
FAILURE CODE [DB11KA] (For machines equipped with emergency engine stop switch) - - - - - - - - - - - - - - 40-789
FAILURE CODE [DB12KK] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-792
FAILURE CODE [DB13KK] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-795
FAILURE CODE [DB19KQ] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-798
FAILURE CODE [DB1LKA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-799
FAILURE CODE [DB1LKB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-802
FAILURE CODE [DB1QMA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-806
FAILURE CODE [DBC0KT] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-834
FAILURE CODE [DBC0MC] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-835
FAILURE CODE [DBC1KA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-836
FAILURE CODE [DBC2KK] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-839
FAILURE CODE [DBC3KK] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-841
FAILURE CODE [DBC9KQ] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-844
FAILURE CODE [DBCLKA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-845
FAILURE CODE [DBCLKB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-847
FAILURE CODE [DBCQKR]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-849
FAILURE CODE [DBCQMA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-850
FAILURE CODE [DBCRKR] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-851
FAILURE CODE [DBV0MC] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-852
FAILURE CODE [DBV1KK] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-853
FAILURE CODE [DBV6KB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-855
FAILURE CODE [DBV7KB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-857
FAILURE CODE [DBVLKA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-858
FAILURE CODE [DBVLKB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-861
FAILURE CODE [DBVQKR] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-864
FAILURE CODE [DBVRKR] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-865
FAILURE CODE [DBVVKR] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-866
FAILURE CODE [DBVWKR] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-867
FAILURE CODE [DDAAL6] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-868
FAILURE CODE [DDAAL6] (For machines equipped with emergency engine stop switch) - - - - - - - - - - - - - - 40-870
HD465-8, HD605-8 40-9

FAILURE CODE [DDACL4] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-873

FAILURE CODE [DDADKA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-875
FAILURE CODE [DDADKY] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-877
FAILURE CODE [DDD7KX]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-878
FAILURE CODE [DDP6L4] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-880
FAILURE CODE [DDTHKA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-882
FAILURE CODE [DDTJKA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-884
FAILURE CODE [DDTKKA]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-886
FAILURE CODE [DDTLKA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-888
FAILURE CODE [DDTMKA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-890
FAILURE CODE [DDTNKA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-892
FAILURE CODE [DDTPKA]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-894
FAILURE CODE [DF10KA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-896
FAILURE CODE [DF10KB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-900
FAILURE CODE [DGE5KX]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-905
FAILURE CODE [DGF1KX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-907
FAILURE CODE [DGR2KB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-909
FAILURE CODE [DGR6KB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-911
FAILURE CODE [DGR6L8] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-912
FAILURE CODE [DGT1KX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-914
FAILURE CODE [DGT4KA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-916
FAILURE CODE [DGT4KB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-918
FAILURE CODE [DGT4KY] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-920
FAILURE CODE [DHA4KA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-922
FAILURE CODE [DHAAMA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-924
FAILURE CODE [DHABMA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-925
FAILURE CODE [DHACMA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-926
FAILURE CODE [DHADMA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-927
FAILURE CODE [DHP4KY] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-928
FAILURE CODE [DHP6KA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-936
FAILURE CODE [DHP6KX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-938
FAILURE CODE [DHP7KA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-944
FAILURE CODE [DHP7KX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-946
FAILURE CODE [DHT5L6] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-958
FAILURE CODE [DHT8ZG] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-962
FAILURE CODE [DHU2KX]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-963
40-10 HD465-8, HD605-8


FAILURE CODE [DHUCKX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-975
FAILURE CODE [DHUDKX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-978
FAILURE CODE [DHUHKX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-980
FAILURE CODE [DHULKX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-982
FAILURE CODE [DHUMKX]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-984
FAILURE CODE [DHUPKX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-986
FAILURE CODE [DHUTKX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-988
FAILURE CODE [DHY9KX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-990
FAILURE CODE [DJF1KA]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-992
FAILURE CODE [DK30KX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-994
FAILURE CODE [DK51L5] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-996
FAILURE CODE [DK53L8] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1001
FAILURE CODE [DKD0L6] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1007
FAILURE CODE [DKH0KX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1009
FAILURE CODE [DKH1KX] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1011
FAILURE CODE [DLF1LC]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1014
FAILURE CODE [DLM3KA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1035
FAILURE CODE [DLM3LC] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1036
FAILURE CODE [DLM3MB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1038
FAILURE CODE [DLT3KA]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1039
FAILURE CODE [DLT3LC] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1040
FAILURE CODE [DSJ0KR] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1052
FAILURE CODE [DV00KB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1053
FAILURE CODE [DW2AKA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1055
FAILURE CODE [DW2AKB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1056
FAILURE CODE [DW2AKY] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1057
FAILURE CODE [DW2AL1] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1058
HD465-8, HD605-8 40-11

FAILURE CODE [DW2ALH] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1059

FAILURE CODE [DW2BKA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1060
FAILURE CODE [DW2BKB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1061
FAILURE CODE [DW2BKY] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1062
FAILURE CODE [DW2BL1] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1063
FAILURE CODE [DW2BLH] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1064
FAILURE CODE [DW35KZ]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1065
FAILURE CODE [DW4BK4] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1069
FAILURE CODE [DW4BMA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1073
FAILURE CODE [DW73KA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1079
FAILURE CODE [DW73KB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1081
FAILURE CODE [DW73KY] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1083
FAILURE CODE [DW7BKB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1086
FAILURE CODE [DW7BKY] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1087
FAILURE CODE [DW7BKZ] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1088
FAILURE CODE [DW7NKZ] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1089
FAILURE CODE [DWD7K4] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1096
FAILURE CODE [DWNDKZ] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1102
FAILURE CODE [DWNDMA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1104
FAILURE CODE [DWNEKZ] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1106
FAILURE CODE [DWNEMA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1108
FAILURE CODE [DWNMKZ] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1110
FAILURE CODE [DX11K4] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1112
FAILURE CODE [DX11MA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1119
FAILURE CODE [DX21MA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1134
40-12 HD465-8, HD605-8

FAILURE CODE [DX22KY] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1139

FAILURE CODE [DX22MA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1140
FAILURE CODE [DX23KA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1142
FAILURE CODE [DX23KB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1143
FAILURE CODE [DX37K4]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1156
FAILURE CODE [DX38K4]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1165
FAILURE CODE [DXHHKA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1220
FAILURE CODE [DXHHKB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1222
FAILURE CODE [DXHHKY] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1224
FAILURE CODE [DY30MA] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1226
FAILURE CODE [DY30MC] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1228
FAILURE CODE [DY30ME] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1231
FAILURE CODE [F@BYNR] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1233
HD465-8, HD605-8 40-13

FAILURE CODE [F@BYNS] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1234

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1235
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1235
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1243
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1246
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP- - - - - - - - - - - - - 40-1248
E-5 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING - - - - - 40-1250
E-6 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING (For machines
equipped with emergency engine stop switch) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1253
E-7 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1256
E-8 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS)
40-1258
E-9 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1260
E-10 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1262
E-11 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL - - - - - - - - - - - - - 40-1265
E-12 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1269
E-13 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES
NOT OPERATE PROPERLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1272
E-14 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION - - 40-1274
E-15 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL - - - - - - - - - - - - - - - - - - - - - - - - - 40-1276
E-16 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED
PROPERLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1278
E-17 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS - - - - - - - - - - - - - - - - - - - - 40-1279
E-18 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1283
E-19 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED- - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1287
E-20 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL - - - - - - - - - - - - - - - - - - - - - - - - - 40-1290
E-21 REARVIEW MONITOR DOES NOT DISPLAY IMAGES WHILE REVERSE LINKED DISPLAY FUNCTION IS
ENABLED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1292
E-22 GUIDE LINE ON REARVIEW MONITOR IS NOT DISPLAYED WHILE GUIDE LINE IS SET - - - - - - - - - 40-1295
E-23 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL- - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1297
E-24 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1299
E-25 MACHINE MONITOR CANNOT BE OPERATED WHEN STARTING SWITCH IS IN OFF POSITION- - - 40-1301
E-26 ALARM BUZZER DOES NOT SOUND - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1302
E-27 ALARM BUZZER DOES NOT STOP SOUNDING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1304
E-28 AISS FUNCTION DOES NOT OPERATE PROPERLY- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1306
E-29 HOIST LEVER DOES NOT OPERATE PROPERLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1308
E-30 FUEL FEED PUMP DOES NOT OPERATE OR DOES NOT STOP AUTOMATICALLY - - - - - - - - - - - - - 40-1310
E-31 TURN SIGNAL LAMP AND WINKER LAMP (HAZARD LAMP) DO NOT OPERATE PROPERLY- - - - - - 40-1313
E-32 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS - - - - - - - - - - - - - - - - - - - - - - - 40-1317
E-33 SMALL LAMP (CLEARANCE LAMP) DOES NOT LIGHT UP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1320
E-34 TAIL LAMP DOES NOT LIGHT UP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1323
E-35 (LOW BEAM) HEAD LAMP DOES NOT LIGHT UP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1326
E-36 (HIGH BEAM) HEAD LAMP DOES NOT LIGHT UP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1328
E-37 NEITHER (LOW BEAM) NOR (HIGH BEAM) HEAD LAMPS LIGHTS UP - - - - - - - - - - - - - - - - - - - - - - 40-1330
E-38 HIGH BEAMS DO NOT LIGHT UP WHILE PASSING SWITCH IS OPERATED - - - - - - - - - - - - - - - - - - 40-1332
E-39 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1334
E-40 DATA DOWNLOADING BY USING WIRELESS LAN CAN NOT BE PERFORMED - - - - - - - - - - - - - - - 40-1336
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) - - - - - - - - - - - - - - - - - - - 40-1337
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) - - - - - - - - - - - - - - - - - - - - - - - - 40-1337
FAILURE MODE AND CAUSE TABLE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1338
40-14 HD465-8, HD605-8

H-1 MACHINE DOES NOT START - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1347

H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE HUNTS) - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1350
H-3 LOCKUP IS NOT RELEASED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1351
H-4 ABNORMALLY LARGE SHOCKS RESULT FROM STARTING OF MACHINE AND GEAR SHIFTING - - 40-1352
H-5 GEAR IS NOT SHIFTED UP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1354
H-6 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN LOCKUP DRIVE MODE AT ALL GEAR
SPEEDS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1357
H-7 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN TORQUE CONVERTER DRIVE MODE
40-1358
H-8 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING AT SOME GEAR SPEED - - - - - 40-1359
H-9 LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED - - - - - - - - - - - 40-1361
H-10 OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1364
H-11 OIL PRESSURE OF TORQUE CONVERTER IS LOW - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1365
H-12 STEERING WHEEL IS HEAVY TO OPERATE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1366
H-13 STEERING WHEEL CANNOT BE OPERATED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1367
H-14 STEERING WHEEL WAGGLES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1368
H-15 FRONT BRAKE DOES NOT WORK ENOUGH - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1369
H-16 REAR BRAKE DOES NOT WORK ENOUGH - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1370
H-17 DUMP BODY RISING SPEED IS LOW - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1372
H-18 HYDRAULIC DRIFT OF DUMP BODY IS LARGE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1374
H-19 DUMP BODY DOES NOT MOVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1375
H-20 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)- - - - - - - - - - - - - - - - - - - - - - - 40-1377
H-21 UNUSUAL NOISE IS HEARD FROM AROUND FAN - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1378
TROUBLESHOOTING OF ENGINE (S-MODE)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1379
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) - - - - - - - - - - - - - - - - - - - - - - - - 40-1379
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION - - - - - - - 40-1380
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1381
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT
START) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1382
S-4 ENGINE STARTABILITY IS POOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1383
S-5 ENGINE DOES NOT PICK UP SMOOTHLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1385
S-6 ENGINE STOPS DURING OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1387
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1389
S-8 ENGINE LACKS POWER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1390
S-9 KDPF GETS CLOGGED IN A SHORT TIME - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1392
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1394
S-11 OIL BECOMES CONTAMINATED QUICKLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1395
S-12 FUEL CONSUMPTION IS EXCESSIVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1396
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) - - - - - - - 40-1397
S-14 OIL PRESSURE DROPS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1398
S-15 FUEL MIXES INTO ENGINE OIL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1399
S-16 WATER MIXES INTO ENGINE OIL (MILKY) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1400
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1401
S-18 UNUSUAL NOISE IS HEARD- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1402
S-19 VIBRATION IS EXCESSIVE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1403
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1404
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1405
S-22 ACTIVE REGENERATION TAKES TIME - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1406
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1407
HD465-8, HD605-8 40-15

ABBREVIATIONS 40 TROUBLESHOOTING
ABBREVIATIONS

and system)

System

Advanced Joystick
Automatic Retarder
Automatic Retarder
the operator.




CDR Engine

Closed-center Load
Sensing System


40-16 HD465-8, HD605-8

40 TROUBLESHOOTING ABBREVIATIONS

and system)

Electronic Control



Exhaust Gas
Recirculation



FOPS Cab and canopy
Structure

Global Positioning
System
Plus) location.

Global Navigation
Satellite System
Plus) location.

HSS

Hydro Static

Communication and
electronic control



HD465-8, HD605-8 40-17


and system)

KCCV Engine
filters.

KCSF Engine

KOMATSU Diesel
Oxidation Catalyst
muffler.

KDPF Engine
Particulate Filter
muffler.
KOMATSU Traction

such as a monitor.

LIN

load.
LVDS


Service
cell phones.

system
activated.

system
activated.
40-18 HD465-8, HD605-8

40 TROUBLESHOOTING ABBREVIATIONS

and system)

PCCS
transmission.

supply pump.

Hydraulic system
(D, PC, etc)
PTP

ROPS Cab and canopy
Structure
ISO 12117-2.

SCR Urea SCR system
of related devices.



Tip-Over Protective
Structure
overturning)

VGT Engine

Variable HorsePower
Control
of the machine.

D: Bulldozer
HD: Dump truck
WA: Wheel loader
HD465-8, HD605-8 40-19

A/C Air Conditioner
A/M Air Mix damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
ENG Engine
F.G. Frame Ground
GND Ground
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/M Transmission
40-20 HD465-8, HD605-8

40 TROUBLESHOOTING GENERAL TROUBLESHOOTING POINTS
RELATED INFORMATION ON TROUBLESHOOTING

GENERAL TROUBLESHOOTING POINTS
k If you remove the radiator cap while the engine remains hot, hot coolant may spray out and burn you. Wait until
the engine is cool.
k Take extreme care not to touch a hot part or be caught in the rotation of the fan blade.
k Before you remove a plug, or cap of a part where oil pressure, hydraulic pressure, or air pressure is applied, first,
release the internal pressure. Then securely connect the test tool.
k When you disconnect wires, remove the key and turn the battery disconnect switch to the OFF position.
k Park the machine on a level area and examine the chocks and parking brake.
k When you work in a group, use signals and allow only authorized persons to approach the machine.
q To troubleshoot is to investigate the cause of a failure. Make repairs immediately to prevent repeat of the failure.
q An important thing when you troubleshoot is to understand the machine and its operation.
q To troubleshoot satisfactorily, it is important to talk with the operator and set a possible cause of failure.
q If you disassembly the machine hastily when it has a failure, you may disassemble unrelated portions and may not be able
to find the cause. As a result, the costs of the man-hours, parts, oil, or grease may increase, and you may lose the confi-
dence of the users and operators. Accordingly, sufficient advance check and proper procedure are necessary for trouble-
shooting.
1. Ask operators these questions.
1) Have any other problems occurred, apart from the problem given?
2) Was there anything different about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there problems with the machine before this?
4) In what conditions did the failure occur?
5) Had any repairs been performed before the failure? When were these repairs performed?
6) Has the same kind of failure occurred before?
2. Perform these checks before you troubleshoot.
1) Examine the machine for symptoms of a problem.
2) Perform the "Check before you start" items.
3) Examine the other check items.
4) Examine other maintenance matters that are considered necessary, which are examined externally.
3. Examine the degree of trouble you see and whether it is a real failure or a problem of machine operation.
When you repeat the trouble as you operate the machine, do not perform procedures or measure items which can increase
the failure.
4. Use the results of the inspection to restrict the probable causes of the failure. Then troubleshoot with the flow diagram to
locate the exact failure.
The basic troubleshooting procedure is as follows.
q Start from the simple points.
q Start from the most likely points.
q Investigate other related parts or information.
5. If the cause is not corrected, a similar failure may occur again, although the apparent failure is repaired. Always find out the
cause of a failure first and repair the root cause of each failure.
HD465-8, HD605-8 40-21

TROUBLESHOOTING POINTS FOR AFTERTREATMENT SYSTEMS 40 TROUBLESHOOTING
TROUBLESHOOTING POINTS FOR AFTERTREATMENT

SYSTEMS
Obey these precautions and changes when you troubleshoot. They are the result of the newly installed aftertreatment systems.
Engine controller shutdown
q When the start switch is turned to the OFF position, the engine controller starts the end procedure. After the end procedure
is completed, the step which turns off the engine controller's power is referred to as "Engine controller shutdown".
q If the start switch is turned OFF and ON before the shutdown of the engine controller, it does not update information in the
engine controller. Then, the troubleshooting of the device may not operate correctly. If this happens, it becomes necessary
to shut down the engine controller. Complete shutdown of the engine controller is made sure when the system operation
lamp goes out.
Loaded Diagnostics Operation To Confirm Failure Correction and Loaded Diag-
nostics Operation To Clear Failure Code in the troubleshooting procedure
k Do not become burned. The aftertreatment devices and their temperature and pressure sensors are hot after
"Loaded Diagnostics Operation To Confirm Failure Correction" or "Loaded Diagnostics Operation To Clear Failure
Code" are run. Troubleshoot or repair after you let the devices cool.
NOTICE
The "Operation to judge the repair result" and "Machine operation to clear the failure code" apply a load to the engine
and are special operations to be performed only when you troubleshoot.
Perform stall operation. To do normal check, refer to the procedure described in TEST AND ADJUST.
NOTICE
Make sure of the fuel level before the operation for "Operation to judge the repair result" or "Machine operation to
clear the failure code".
To examine the fuel level, see TEST AND ADJUST, "SET AND OPERATE OF MACHINE MONITOR" and "SERVICE MODE".
1. Tips
q The engine controller monitors the operation of engine-related components. It monitors aftertreatment devices, and
shows a failure code on the monitor when a problem is found. It deletes the failure code after the failure is corrected.
The monitored items include: sensors, actuators, electric wiring, catalyzer, etc.
q The engine controller deletes the failure code when it troubleshoots and the failure is corrected. However, the failure
code is possibly deleted during engine controller shutdown and the failure may remain. It may be necessary to apply a
load to the engine to troubleshoot. Open and short circuits are diagnosed when you turn the start switch to the ON po-
sition after you complete the repair.
q If exhaust gas temperature or flow rate is below the specified value, the engine controller may not activate troubleshoot-
ing of aftertreatment devices or other functions. You should always perform "Loaded Diagnostics Operation To Confirm
Failure Correction" or "Loaded Diagnostics Operation To Clear Failure Code" after the repair. These operations are to
run the engine, and rev up or load the engine to activate and meet the conditions to troubleshoot.
2. Loaded Diagnostics Operation To Confirm Failure Correction
q This operation is performed to make sure a failure is corrected when the failure code is already cleared (described lat-
er). Or, it is cleared before the failure is corrected.
q After the repair is completed, run the engine and the machine until the exhaust gas temperature and flow rate exceed
the specified value. To determine if the failure is corrected, let the engine controller activate troubleshooting of the af-
tertreatment devices. If the failure is corrected, the failure code is not be shown.
REMARK
q Failure codes that require "Loaded Diagnostics Operation To Confirm Failure Correction" or "Loaded Diagnostics Op-
eration To Clear Failure Code" after repair, a "Notice" mark is recorded in the related information record of each failure
code as described. The procedure is given at the end of each failure code.
q When you perform "Loaded Diagnostics Operation To Confirm Failure Correction" or "Loaded Diagnostics Operation
To Clear Failure Code", make sure that the fuel level in the tank is enough. To examine the fuel level, see TEST AND
ADJUST, "SET AND OPERATE OF MACHINE MONITOR" and "SERVICE MODE".
40-22 HD465-8, HD605-8

40 TROUBLESHOOTING TROUBLESHOOTING POINTS FOR AFTERTREATMENT SYSTEMS
3. Loaded Diagnostics Operation To Clear Failure Code

q This operation is performed to clear a failure code not cleared when you turned the start switch to ON after the failure
is repaired.
q After the repair is completed, run the engine and the machine until the exhaust gas temperature and flow rate exceed
the specified value. To determine if the failure is corrected, let the engine controller activate troubleshooting of the af-
tertreatment devices. If the failure is corrected, the shown failure code will go out.
Remove the Failure Code
"Remove failure code" refers to a manual delete of a failure code from the engine controller that is in operation. These two
"Remove Failure Code" functions are added.
"Engine Controller Active Fault Clear"

q It is now possible to delete the failure code from the machine monitor without using INSITE.
q When operation conditions to correctly troubleshoot are not engaged, this function is used to troubleshoot, after the cause
of the failure is repaired. If the machine is operational, perform "Loaded Diagnostics Operation To Confirm Failure Correc-
tion" or "Loaded Diagnostics Operation To Clear Failure Code" to delete the failure codes.
q For details, see TEST AND ADJUST, "SERVICE MODE" and "OPERATE ENGINE CONTROLLER ACTIVE FAULT
CLEAR TEST MENU" under "SET AND OPERATE OF MACHINE MONITOR".
When you cannot clear failure codes by the "Loaded Diagnostics Operation To
Confirm Failure Correction" and "Loaded Diagnostics Operation To Remove Fail-
ure Code"
q Although the cause of the failure is repaired, the relevant failure code may not be able to be deleted because of other fail-
ures. Details and the measures to take are as shown below.
When failure codes are not deleted: Functional restrictions caused by other fail-
ures
q The failure code may not be able to be deleted because of functional restrictions (regeneration disable, or others) caused
by other failures. Operation and procedure required to delete the code are given in "TROUBLESHOOTING BY FAILURE
CODE (DISPLAY OF CODE)".
q Measures to take:
Use the procedure and remove the failure code.
q Examples:
1) The failure code does not clear because of unusual high or low voltage, or communication error of a failure code is
shown for related components. (open or short circuit)
2) The failure code is not deleted because correct values are not input from a sensor (a failure code for a related sensor
is shown instead).
3) The failure code is not deleted because a failure code that disables automatic regeneration or manual stationary regen-
eration of the aftertreatment devices is shown.
How to identify the failure code to be repaired
Among failure codes shown on the "Abnormality Record" screen of the monitor, identify failure codes that have these conditions
as a code to be repaired.
1. Failure codes shown with "E" ("E" is shown on the left of failure code. See the figure.)
q Examine the "Abnormality Record" screen and identify all failure codes where "E" is now shown as a code to be re-
paired.
q The failure codes are shown in the upper row from the "E" on the "Abnormality Record" screen. (See the figure.)
2. Failure codes shown without "E", their (SMR) at the last occurrence (at previous work time) is used as the most recent
failure.
q The failure codes with recently found records, shown without "E" may be in the condition that their abnormalities are
not cleared (*1). Because of that, see "Troubleshooting by failure code" to identify them as a code to be repaired.
q The failure codes are shown on the "Abnormality Record" screen in an up sequence. (See the figure.)
*1: Corresponds to a failure code that is deleted when you turn the start switch to the OFF position. Also when you stop the
engine, although the repair is not completed.
HD465-8, HD605-8 40-23

1: Area where "E" is shown

2: Area where the most recent SMR is shown
REMARK
Display of "E" on the "Abnormality Record" screen
1. Transition of "E" shown with failure code has the pattern that follows.
The table shows the display of "E" on the "Abnormality Record" screen of the machine monitor. This display shows when
the start switch is turned ON after the start switch was turned OFF which stopped the engine controller.
Occurrence of failure code (with or without "E")

Transition
Before repair Make sure that the repair is completed
pattern After repair Remarks
(in failure)
The "E" is not shown after You are able to turn the start switch ON, when
Failure A "E" No display
the repair is completed. the repair is completed correctly.
The "E" does not go out To determine if the repair is completed cor-
Failure B "E" "E" when the repair is com- rectly, it is necessary to perform "Loaded Diag-
pleted. nostics Operation To Remove Failure Code".
q See the most recent SMR on the "Abnormal-
ity Record" screen to determine condition for
Once the engine controller repair. "E" alone cannot determine that the
stops, the "E" goes out, failure is deleted.
Failure C No display No display
although the repair is not q To determine if the repair is completed cor-
completed. rectly, it is necessary to perform "Loaded Di-
agnostics Operation To Confirm Failure
Correction".
2. The number of occurrences increases each time you turn the start switch to ON, unless you will delete the "E" of the failure
code.
40-24 HD465-8, HD605-8

HD465-8, HD605-8 40-25

40-26 HD465-8, HD605-8

HD465-8, HD605-8 40-27

SEQUENCE OF EVENTS IN TROUBLESHOOTING 40 TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
40-28 HD465-8, HD605-8

40 TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
HD465-8, HD605-8 40-29

CHECKS BEFORE TROUBLESHOOTING 40 TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

Engine, lubricating oil, and coolant
No. Item Criteria Remedy
1 Examine for unusual noise and smell - Repair
2 Examine around the engine for dirt - Remove
3 Examine the engine for water leakage - Repair
4 Examine the engine for oil leakage - Repair
5 Examine the fuel line for leakage - Repair
6 Examine the radiator for blockage - Remove
7 Examine the aftertreatment devices and remove the dirt - Remove
Examine the aftertreatment devices for exhaust gas

8 - Repair
leakage
9 Examine the fuel level and type - Add fuel
10 Examine the fuel for unwanted material - Clean and drain
11 Examine the fuel prefilter - Replace
12 Examine the primary fuel filter - Replace
13 Examine the engine oil level (in the oil pan) and type Between H and L Add engine oil
14 Examine the coolant level (in the over flow canister) Between H and L Fill with coolant
Blockage is indicated on
15 Examine the air cleaner for blockage Clean or replace
the machine monitor.
Hydraulic and mechanical equipment
1 Examine for unusual noise and smell - Repair
2 Make sure there is no oil leakage - Repair
3 Examine the hydraulic oil level Between H and L Fill with oil
4 Examine the hydraulic oil screen filter - Clean or replace
5 Examine the hydraulic oil filter - Replace
6 Examine the transmission case oil level Between H and L Fill with oil
7 Examine the differential case oil level - Fill with oil
8 Examine the final drive case oil level - Fill with oil
9 Bleed air - Bleed air
Check of work equipment, cylinders, linkage and hoses

10 - Repair
for breakage, wear and clearance
40-30 HD465-8, HD605-8

40 TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
Electrical equipment
Examine around batteries and remove unwanted mate-

1 - Remove
rial
Examine that the battery connections are tight and cor-

2 - Tighten or replace
rosion free
Inspection of the alternator for loose or corroded con-

nections
Inspection of the starting motor for loose or corroded

connection connections are tight and corrosion free
5 Inspect the battery voltage (with engine stopped) 20 to 30 V Charge or replace battery
6 Examine the battery electrolyte level Between H and L Fill or replace
Examine the wire harness for color changes, heat dam-

7 - Replacement or repair
age, or weak insulation
Make sure the wire harness clamp is secure and the

8 - Repair
harness is not loose
9 Inspect for ground - Repair
10 Inspection of a loose connector and a damaged lock - Replacement or repair
Inspection of connector pins for corrosion, bends and

11 - Replacement or repair
deformation
Inspection of the connector for water and unwanted

12 - Dry, clean or replace
material
13 Examine the wire harness for open or short circuit - Replacement or repair
14 Inspect for a blown fuse or corrosion - Replace
15 Inspection of the circuit breaker - Push the reset switch
Make sure of the alternator voltage (when engine speed 27.5 to 29.5 V after a short
16 Replace
is moderate or higher) period of operation
Examine the sound of the battery relay (when the start

17 - Replace
switch is turned to ON or OFF)
18 Examine and clean the rearview camera - Clean or repair
External
1 Check of undercarriage - Repair
2 Check of handrails and steps - Repair
3 Examine the mirrors - Clean or repair
HD465-8, HD605-8 40-31

CHECKS BEFORE TROUBLESHOOTING 40 TROUBLESHOOTING
Internally
1 Examine the gauges and monitors - Clean or replace
2 Examine the seat belt - Repair
40-32 HD465-8, HD605-8

40 TROUBLESHOOTING INSPECTION PROCEDURE BEFORE TROUBLESHOOTING
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING

WALK-AROUND CHECK
Before starting the engine, look around and under the machine to check for any loose nuts or bolts, leakages of oil, fuel, or
coolant, and check the condition of the work equipment and hydraulic system.
Examine that the connectors are tight, wire harness not loose, and accumulation of dust in areas that are at too high a temper-
ature.
k Accumulated combustibles around hot engine parts such as exhaust pipes, aftertreatment devices, turbocharger,
etc. and fuel or oil leakages may cause a machine fire. Be sure to examine fully and repair any failures.
q Examine for unusual noise and smell
Examine for an unusual noise and odor.
If the machine continued to be operated with noise or odor issues, the cause of it may harm the machine. Stop the operation
immediately once you recognize it.
q Make sure to remove any dirt from around the engine.
Find any accumulated dirt around the engine and any flammable (leaves, twigs) on hot engine parts such as the exhaust
pipes, aftertreatment devices turbocharger. If any, remove them.
q Look around the engine for water leakage
Examine the cooling system for leakage. If any leakage is found, repair it.
q Look for engine oil leakage
Look for engine oil leakage. If any leakage is found, repair it.
q Examine the fuel line for leakage
Examine the fuel line for leakage, check hoses and pipes for damage. If any problem is found, repair it.
q Inspect the radiator and remove any dirt
Look for any accumulated dirt and any flammable unwanted material (leaves, twigs) around the radiator. If any, remove
them.
For the removal of dirt from the radiator, see the Operation and Maintenance Manual to clean and test the radiator core.
q Look around aftertreatment devices and remove unwanted material
Look for and remove any accumulated dirt and unwanted material (leaves, twigs) around aftertreatment devices.
q Examine aftertreatment devices for exhaust gas leakage
Examine, and if any problem is found, repair it. Inspect the pipes, which connect turbocharger and KDPF, for exhaust gas
leakage (soot attached) from the connection part of KDPF. Also, look for exhaust gas leakage (urea particle attached) from
pipes which connect KDPF and the body.
q Check of work equipment, cylinders, linkage and hoses for breakage, wear and clearance
Check the work equipment, cylinders, linkage, and hoses for breakage, wear, and clearance. If any abnormality is found,
repair it.
q Check of hydraulic equipment, hydraulic tank, hoses, and joints for oil leakage
Inspect for oil leaks. If any problem is found, repair it.
q Look around batteries and remove the dirt
Look for any accumulated dirt and flammable matter (leaves, twigs) around the batteries. If any, remove them.
q Examine the wheels (tires, rims) for unusual wear, loose bolts, and oil leakage
If any problem is found, repair or tighten any loose bolts.
q Examine the handrails and steps for anything unusual or loose bolts
If any problem is found, repair or tighten any loose bolts.
q Examine and clean the rearview mirrors
Inspect the rearview mirror for any problem. If any, repair it.
Clean the mirror and adjust its angle to see the rear of the machine from the operator's seat.
q Examine the gauges and monitors for problems
Make sure that gauges and monitors in the operator's cab are problem free. If any problem is found, replace with a new one.
Clean up the surfaces.
q Inspect the seat belt and attached bolts or nuts
Examine the hook, the lock, and hook mount to attach for damage. If any problem is found, repair it.
HD465-8, HD605-8 40-33

TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40 TROUBLESHOOTING
TESTING IN ACCORDANCE WITH TESTING PROCEDURE

CHECK FUEL LEVEL AND TYPE
k Fuel is highly flammable and dangerous. Stay away from fire.
k When you add fuel, be careful not to add too much.
k Wipe off any spilled fuel. If fuel spills over soil or sand, remove all the fuel and soil or sand together.
1. Turn the engine start switch to ON and make sure of the fuel level
with the fuel gauge (1) on the monitor.
After you examine the fuel level, turn the start switch back to OFF.
2. If the fuel level is low, open fuel fill cap (F) on the fuel tank. Add
fuel through the fill port to a level enough examine.
REMARK
If the breather hole in the cap is clogged, the pressure in the tank
will go down. This may cause the fuel to stop its flow. To prevent
this, clean the breather hole from time to time.
CHECK IMPURE INGREDIENT IN FUEL

1. Prepare a container (below the drain hose) to receive fuel.
2. Loosen the drain valve to release the unwanted material and water
(in the bottom) together with the fuel.
3. When only the clean fuel flows out, close the drain valve.
CHECK FUEL PREFILTER

k Immediately after the engine is stopped, its parts continue to be very hot. Do not replace the filter immediately.
Wait until all parts are cool before you start the work.
k High pressure is generated in the engine fuel system when the engine runs.
Replace the filter after the engine stops and you wait a minimum 30 seconds until the inner pressure is released.
k Keep fire distant.
NOTICE
q Komatsu genuine fuel filter cartridges adopt a special filter with high-efficiency filter properties. Use Komatsu gen-
uine parts when you replace them.
q The common rail fuel injection system used on this machine has more precise parts than those in the standard
injection pump and nozzle. If any filter other than a Komatsu genuine fuel filter cartridge is used, unwanted mate-
rials may enter and problem may occur in the injection system. Do no use alternative parts.
40-34 HD465-8, HD605-8

40 TROUBLESHOOTING TESTING IN ACCORDANCE WITH TESTING PROCEDURE
q During test or maintenance of the fuel system, be sure that any unwanted material does not enter the fuel system.
If any dust or other material attaches to any part, clean the part fully with clean fuel.
q When the filter cartridge is removed, fuel drops from the filter head. To prevent leakage of fuel, do not leave the
machine with the filter cartridge removed.
Items to be prepared
q Container to receive the fuel
q Filter wrench
When you replace the primary filter cartridge (each 1000 hours), replace the initial fuel filter first.
1. Close the fuel supply valve (1) of the fuel tank.
2. Loosen the bolts (2) (2 pieces) and open the cover (3).
3. Put a container below the initial fuel filter to catch the fuel.
4. Loosen the drain valve (5) and drain water and unwanted material
from the transparent container (6). Also drain all the fuel from the
initial fuel filter cartridge (4).
5. Turn the initial fuel filter cartridge (4) counterclockwise using the
filter wrench, and remove it.
Initial fuel filter cartridge (4) and transparent container (6) are inte-
grated.
6. Make sure the drain valve (5), which is provided in the lower part
of transparent container (6) of the new filter cartridge, is firmly
tight.
3 Value to tighten:
2.5 to 3.4 Nm {0.25 to 0.35 kgm}
HD465-8, HD605-8 40-35

7. Clean the filter head.
NOTICE
It is not necessary to fill the filter cartridge with fuel.
The cap (A) is provided to keep the dirt or dust out of the filter
cartridge.
8. Cover the seal surface with a thin layer of oil.

9. Remove the filter cartridge cap (A) and install it to the filter head.
When you install the filter cartridge, tighten it hand tight until the
surface touches the seal surface of the filter head.
If the filter cartridge is tightened too much, the gasket is damaged
and this will cause the leakage of fuel. If it is not tightened enough,
fuel will drain through the opening in the gasket. Be sure to ob-
serve the angle to tighten.
10. Tighten it 1/2 to 3/4 turns by using the filter wrench.
Take care not to damage or deform the filter cartridge.
11. Make sure that the drain valve (5) is tightened correctly.
12. Open the fuel supply valve (1) of the fuel tank.
13. After the filter cartridge is replaced, start the engine and run it at low idle for 10 minutes.
14. Examine the filter seal surface and the mount face of the transparent container for fuel leakage.
If there is any leakage of fuel, examine how tight the filter cartridge is.
If fuel leakage continues, perform the steps 1 to 5 to remove the filter cartridge. Make sure there is no damage or unwanted
material on the gasket surface. If there is, replace it with a new filter cartridge and repeat the steps 6 to 15.
15. Close the cover (3) with the bolts (2) (2 pieces).
CHECK MAIN FILTER
k Immediately after the engine is stopped, its parts continue to be very hot. Do not replace the filter immediately.
Wait until all parts are cool before you start the work.
k High pressure is generated in the engine fuel system when the engine runs. Replace the filter after the engine
stops and you wait a minimum 30 seconds until the inner pressure is released.
k Keep fire distant.
k When using the fuel supply pump, do not loosen the air bleed plug of the fuel circuit. The fuel circuit is pressurized
while the fuel supply pump is operated. If the air relief plug is loosened at this time, fuel may spray out and it is
dangerous.
NOTICE
q Komatsu genuine fuel filter cartridges adopt a special filter with high-efficiency filter properties. Use Komatsu gen-
uine parts when you replace them.
q The common rail fuel injection system used on this machine has more precise parts than those in the standard
injection pump and nozzle. If any filter cartridge other than a Komatsu genuine fuel filter cartridge is used, unwant-
ed materials may enter. Thus, a problem may occur in the injection system. Do no use alternative parts.
q During test or maintenance of the fuel system, be sure that any unwanted material does not enter the fuel system.
If any dust or other material attaches to any part, clean the part fully with clean fuel.
q When the filter cartridge is removed, fuel drops from the filter head. To prevent the flow of fuel, do not leave the
machine with the filter cartridge removed.
40-36 HD465-8, HD605-8

Items to be prepared
q Container to receive the fuel
q Filter wrench
1. Close the fuel supply valve (1) of the fuel tank.
2. Put a container below the filter cartridge (2) to catch the fuel.
3. Turn the filter cartridge (2) counterclockwise by using the filter
wrench, and remove it.
4. Clean the filter head.
5. Cover the seal surface with a thin layer of oil.
6. Install the new filter cartridge to the filter head.

When you install the filter cartridge, tighten it hand tight until its
surface touches the seal surface of the filter head. Then tighten the
filter cartridge 1/2 to 3/4 turns.
NOTICE
q Do not fill the new filter cartridge with fuel.
q Remove the cap (A) at the middle and install the filter car-
tridge.
If the filter cartridge is tightened too much, the gasket is damaged
and this will cause the leakage of fuel. If it is not tightened enough,
fuel will drain through the opening in the gasket. Be sure to ob-
serve the angle to tighten.
When you tighten the filter cartridge using the filter wrench, be careful not to scratch or otherwise damage the filter.
7. After you complete the replacement of filter cartridge (2), bleed air from the circuit.
1) Move the switch for the fuel supply pump (3) to ON position.
Lamp (4) flashes and the fuel supply pump operates.
After the specified time (approximately 7 minutes), the lamp (4)
goes out automatically and the fuel supply pump stops.
When the lamp (4) goes out, the air released is completed.
2) Start the engine.
If the engine does not start, all the air may not be bled. In this
case, repeat the operation of Step 7.
8. After you complete the air bleed, start the engine and inspect the
filter seal surface for fuel leakage.
If there is any leakage of fuel, make sure the filter cartridge is tight.
HD465-8, HD605-8 40-37

If fuel leakage remains, perform Steps 2 to 3 to remove the filter cartridge. Inspect for any damage or stuck unwanted ma-
terial on the gasket surface. Replace the filter cartridge with a new one (if necessary) and repeat Steps 4 to 7.
OIL PAN - CHECK ENGINE OIL LEVEL AND TYPE
k Immediately after the engine is stopped, its parts and oil are very hot and may cause burn injury. Wait until all parts
are cool before you start work.
REMARK
q Wait for a minimum of 15 minutes after you stop the engine, (after engine operation), and examine the engine oil level.
q You can also make the oil level check when the engine runs at low idle. When you examine at low idle, use this procedure.
q Make sure that the gauge of engine coolant temperature is in the white range.
q Remove the oil fill cap.
1. Pull out the oil level gauge (G) and wipe off the oil.
2. Fully put the oil level gauge (G) into its pipe, then pull it out.
It is correct if the oil level is between marks H and L.
The oil level indication is on either side of the dip gauge. One side
is for when the engine is stopped (ENGINE STOPPED). The other
side for when the engine runs at low idle (ENGINE AT IDLE).
To check the oil level, use the face with ENGINE STOPPED mark
and check while the engine is stopped.
3. If the oil level is below L mark, add oil through the oil fill port (F).
4. If the oil level is above H mark, remove the drain plug (1) and
loosen the drain valve (2) to drain the extra oil.
5. Examine the oil level again.
6. If the oil level is proper, tighten the oil fill cap (F) tightly.
CHECK COOLANT LEVEL (RESERVOIR TANK)

k Do not open the radiator cap unless necessary. When you inspect the coolant level, examine it through the reserve
tank when the engine is cold.
k Immediately after the engine is stopped, the coolant is hot and pressure is accumulated in the radiator.
You may get a burn injury when you remove the cap in this circumstance. Always wait for the temperature to go
down, turn the cap slowly to release the pressure, then remove the cap with care.
40-38 HD465-8, HD605-8

If the coolant in the reserve tank is not sufficient

1. Make sure that the coolant level in the reserve tank (1) is between
FULL and LOW marks. If it is not sufficient, remove the cap (2) and
add the coolant to the FULL mark.
If no coolant is left in the reservoir tank

2. Remove the cap (2) of the reserve tank (1) and examine the
coolant level. If no coolant is left, add the coolant with this proce-
dure.
3. Remove the bolts (3) (4 pieces), and remove the upper cover (5)
of the secondary tank (4).
4. Remove the bolts (6) (4 pieces), and remove the upper cover (7)
of the radiator.
HD465-8, HD605-8 40-39

5. Examine the surface temperature of the radiator cap (8) to make

sure that it is not hot to bare fingers. If not hot, loosen the radiator
cap (8) and secondary tank cap (9) a bit to release the pressure.
6. Remove the radiator cap (8) and secondary tank cap (9), and add
the coolant in the radiator.
REMARK
Do not add the coolant in the secondary tank (4). The coolant may
flow out from the radiator.
7. Add the coolant in the reserve tank (1).
REMARK
If the coolant is not sufficient, check for a leakage.
8. Make sure that there is no oil in the engine coolant or any other
problem.
9. After you add the coolant, tighten the radiator cap (8) and
secondary tank cap (9) tightly.
CHECK CLOGGING OF AIR CLEANER

k Using compressed air is dangerous. Dirt is blown and may cause personal injury.
Always wear protective eyeglasses, dust breather guard, or other protection equipment.
k When you remove the outer element from the air cleaner body, it is dangerous to pull it out by force. When you
work in high areas or where the steps are unsatisfactory, be careful not to fall. Be careful to remain stable when
you pull out the outer filter element.
NOTICE
q The electrical blockage sensor and dust gauge are used to indicate the blockage of the air cleaner. The blockage
sensor indicates the clean time of the air cleaner element and the dust gauge indicates the level of blockage.
Examine the dust gauge before you operate the machine. Then there is no reason to clean the air cleaner element
during operation.
q Do not clean the element before the blockage caution lamp on the machine monitor lights up. Also, do not clean
the element until the yellow piston of the dust gauge goes into its adjacent red area (7.5 kPa, {0.076 kg/cm2}).
If the element is cleaned frequently before the blockage caution lamp on the machine monitor lights up, the air
cleaner performance will decrease. Also, before the yellow piston of the dust gauge goes into the red area (7.5 kPa,
{0.076 kg/cm2}), the air cleaner performance will decrease.
In addition, while you clean, dirt stuck to the element may fall into the element.
q If there is any entry of dirt into the engine, damage is possible. Be sure to stop the engine before you examine,
clean, or service the air cleaner. Do not examine, clean, or service the air cleaner in windy conditions, or in a dusty
area.
In addition, while you clean, dirt stuck to the element may fall into the element.
q If the outer element is cleaned 6 times or used throughout a year, replace it. Replace the inner element at the same
time.
40-40 HD465-8, HD605-8

Clean the element when the yellow piston shown in gauge (1) goes
into the red (7.5 kPa {0.076 kg/cm2}) position.
After you clean, push the dust gauge switch to set it.
If the yellow piston goes into the red (7.5 kPa {0.076 kg/cm2}) area a
short time after it is cleaned, replace the element.
Electrical air cleaner blockage sensor

Clean the air cleaner element when the yellow piston of dust gauge (1)
display goes into the red (7.5 kPa {0.076 kg/cm2}) area. Clean the air
cleaner element when the blockage caution lamp (2) of the machine
monitor lights.
OUTER ELEMENT - CLEAN

NOTICE
q Never remove the inner element. Dust may enter and cause an engine failure.
q Do not use the removed inner element more than once. Make sure to replace the inner element when you replace
the outer element.
q When you clean an element, do not hit with it or hit it with objects.
q If folds, gaskets, or seals on an element are damaged, do not use the element.
q Wrap new elements that are not in service, and keep them in a dry area.
1. Stop the engine.
2. Remove the clips (1) (12 positions) and remove the cover (2).
HD465-8, HD605-8 40-41

3. Hold the outer element (3). Rock it lightly up and down and right
and left and turn it as you pull the outer element (3) out.
4. When the outer element (3) is removed, make sure that the inner
element (4) does not come off or incline.
If it is at an angle, push it straight to the bottom with your fingers.
5. Remove the outer element (3). Cover the inner element (4) with a
clean rag to prevent unwanted material from entry.
6. Clean the dust stuck in the air cleaner body (5) and on the cover
(2) by using a clean brush.
7. If any dust is attached to the vacuator valve (6) installed to the

cover (2), remove it.
8. Make sure the lip of vacuator valve (6) has no crack.
If there is any crack, replace it with a new one.
9. When the outer element is cleaned 6 times or used for 1 year,
replace it.
q When it is necessary to replace an element: Replace the inner
and outer with new elements.
q When it is not necessary to replace the element, clean the out-
er element. Continue to clean. Refer to procedure.
10. Blow dry compressed air (0.2 MPa {2.1 kg/cm2} or less) from the
inner side of the element, out along the folds.
11. Blow compressed air along the folds from the out side, then blow
again from the inner side.
12. After you clean the outer element, illuminate the inner side of the
element with an electrical light to examine.
If any hole or thin area is found, replace the outer element.
13. Remove the rag or cover attached to the inner element (4).
14. Examine the seal of the cleaned or new element for the stuck dirt
and oil and wipe them off.
15. Push the outer element (3) straight into the air cleaner body (5)
with your fingers.
Hold the outer element (3). Rock the outer element (3) lightly up
and down, right and left, while you push it in. You can put it in eas-
ily.
k Inspect O-ring (7) for damage before you install the cover (2). If it is damage, use a new o-ring.
16. Install the cover (2) as follows.
40-42 HD465-8, HD605-8

1) Make sure that O-ring (7) is installed to cover (2).

2) Align the cover (2) with the element.
Put the cover (2) with the valve (6) right at the bottom into air
cleaner body (5).
3) Lock the clip points (1) (12 positions) to the lip on the air
cleaner body (5).
Lock the clips (1) diagonally, (top and bottom, right and left) in
the same procedure as when you tighten the bolts.
4) When the cover (2) is installed, make sure that the clearance
between air cleaner body (5) and cover (2) is not too large.
If the clearance is too large, remove the cover (2), and then
install it again.
17. Push the switch of the dust gauge and set the yellow piston.
The blockage caution lamp illuminates immediately after you clean
the outer element. Replace the two elements, inner and outer. The
yellow piston touches the red line (7.5 kPa {0.076 kg/cm2) imme-
diately after you clean the outer element. Replace the two ele-
ments, inner and outer.
REPLACE ELEMENT
1. Stop the engine.
2. Remove the clips (1) (12 positions) and remove the cover (2).
3. Hold the outer element (3). Rock it lightly up and down and right
and left and turn it as you pull the outer element (3) out.
Do not remove the inner element (4) at this time.
4. When the outer element (3) is removed, make sure that the inner
element (4) does not come off or incline.
If it is at an angle, push it straight to the bottom with your fingers.
5. Remove the outer element (3). Cover the inner element (4) with a
clean rag to prevent dirt or dust entry.
6. Clean the dust stuck in the air cleaner body (5) and on the cover
(2) by using a clean rag or brush.
HD465-8, HD605-8 40-43

7. If any dust is attached to the vacuator valve (6) installed to the

cover (2), remove it.
8. Make sure the lip of vacuator valve (6) has no crack.
If there is any crack, replace it with a new one.
9. Remove the inner element (4), and then quickly install the new
inner element.
Install the inner element tightly to not let it move.
10. Push the new outer element (3) in straight with your fingers into the
air cleaner body.
Hold the outer element (3). Rock the outer element (3) lightly up
and down, to the right and left while you push it in. You can put it
in easily.
11. Install the cover (2) refer to the procedure.
1) Replace the O-ring (7) with a new one.
2) Align the cover (2) with the element.
Put the cover (2) with the valve (6) right at the bottom into air cleaner body (5).
3) Lock the clip points (1) (12 positions) to the lip on the air cleaner body (5).
Lock the clips (1) diagonally, (top and bottom, right and left) in the same procedure as when you tighten the bolts.
4) When the cover (2) is installed, make sure that the clearance between air cleaner body (5) and cover (2) is not too large.
If the clearance is too large, remove the cover (2), and then install it again.
12. Push the switch of the dust gauge and set the yellow piston.
CHECK HYDRAULIC OIL LEVEL

k Immediately after the engine is stopped, its parts are very hot, and may cause burn injury. Wait until all parts are
cool before you start work.
k When you remove the oil fill cap, the oil may spray out. Turn it slowly to release the internal pressure, then remove it.
1. Inspect the oil level with the view gauge (G).
If the oil is seen from the view gauge (G), the oil level is correct.
2. If the oil is not seen from the view gauge (G), add the oil through
the oil fill port (F).
CHECK HYDRAULIC OIL STRAINER

k When you remove the oil fill cap, the oil may spray out. Turn it slowly to release the internal pressure, then remove it.
40-44 HD465-8, HD605-8

1. Lower the dump body and stop the engine.

2. Turn the cap of oil fill port (F) gradually to release the internal pres-
sure, and remove the cap.
3. Remove the cap (1) of the hydraulic tank screen filter (2 positions).
4. Take out the screen filter from its case (2).
5. Clean the screen filter and its case 2).
6. After you examine and clean it, put the screen filter in its case (2).
7. Tighten the cap (1) of the hydraulic tank screen filter.
At this time, replace the o-rings.
8. Install the cap of oil fill port (F).
CHECK HYDRAULIC FILTER

cool before you start the work.
k When you remove the oil fill cap, the oil may spray out. Turn the cap slowly to release the internal pressure, then
remove it.
1. Stop the engine.
2. Turn the cap of oil fill port (F) to release the internal pressure
before you remove.
3. Remove the bolts (1) (4 pieces), and remove the cover (2).
4. Remove the O-ring (3), spring (4), valve (5), strainer (6), and
element (7).
5. Clean the inner side of the case, valve (5), and screen filter (6).
6. Prepare a new element. Install the element, strainer, valve, and
spring to the case.
7. Replace the O-ring with a new one. Apply a thin layer of oil, and
install it.
8. Install the cover (2) with the bolts (1) (4 pieces).
NOTICE
If the torque converter oil temperature gauge indicates in the white range, replace the element immediately. If the hydrau-
lic oil filter blockage caution lamp (if equipped) illuminates while the engine runs, replace the element immediately.
HD465-8, HD605-8 40-45

CHECK OIL LEVEL IN TRANSMISSION CASE

k The oil level changes with the oil temperature. Inspect the oil level after you complete the warm-up operation.
k Be sure to inspect the oil level while you run the engine at low idle and after you complete the warm-up operation.
Consider the oil level check when the engine is stopped only as a guide.
2. Run the engine at low idle and examine the oil level with the "Low
temperature" indication on the view gauge (G2).
It is correct if the oil level is between marks H and L.
REMARK
Use the view gauge (G1) as a guide for examine the oil level when
the engine is stopped.
3. If the oil is not sufficient, add oil through the oil fill port (F).
CHECK OIL LEVEL IN DIFFERENTIAL CASE

k Immediately after the engine is stopped, its parts are very hot, and may cause a burn injury. Wait until all parts are
cool before you start the work.
k When you remove the plug, oil may spray out. Turn the plug slowly to release the internal pressure, then remove
it carefully.
1. Remove the plug (G).
2. Make sure that the oil level is near the lower edge of the plug hole.
If the oil level is low, add oil until the oil level comes near the lower
edge of the plug (G) hole.
3. Install the plug G).
CHECK OIL LEVEL IN FINAL DRIVE CASE

k If there is remaining pressure in the case, the oil or plug may jump out. Turn the plug slowly to release the pres-
sure, then remove it carefully.
1. Stop the machine when the "TOP" mark is at the top and the drain
plug (P) is at the bottom.
2. Remove the plug (G). Then, make sure that the oil level is near the
lower edge of the plug hole.
If the oil level is low, add oil until the oil level comes near the lower
edge of the hole of the plug (G).
3. Install the plug G).
BLEED AIR FROM FUEL SYSTEM

To bleed air from the fuel system, see TEST AND ADJUST, "BLEEDING AIR FROM FUEL SYSTEM".
40-46 HD465-8, HD605-8

BLEED AIR FROM HYDRAULIC SYSTEM

To bleed air from the hydraulic system, see TEST AND ADJUST, "BLEED AIR FROM STEERING CYLINDER CIRCUIT" and
"BLEED AIR FROM BRAKE CIRCUIT".
METHOD FOR CHECKING ELECTRIC EQUIPMENT METHOD
Make sure that the battery connections are tight and corrosion free.
1. Make sure that the battery connections are tight and corrosion free.
Inspection of the alternator for loose or corroded connections

2. Inspect alternator connections B (E09), R (E01) and E (E06) for an
open circuit. Make sure the connections are tight and corrosion
free.
Inspection of the starting motor for loose or corroded connection connections are tight and corrosion free
3. Inspect start motor connections B (1) and (2) for an open circuit.
Make sure the connections are tight and corrosion free.
Inspect the battery voltage (with engine stopped)

4. Inspect the battery voltage with a meter (with engine stopped).
Inspect the battery electrolyte level

5. Inspect the battery electrolyte level. Refer to the procedure.
k Inspect the battery electrolyte level before you operate the machine.
k Do not use the battery while its electrolyte level is below "LOWER LEVEL". If it is used with the electrolyte low, it
starts to deteriorate, its service life is decreased, and it may explode.
k The battery gives off a flammable gas that can explode. Do not bring open flame near it.
k Battery electrolyte is dangerous. Take care that it does not touch your eyes or skin. If it does, clean it with water
and speak to your doctor.
NOTICE
q Do not add the electrolyte to the battery exceeding UPPER LEVEL line. If the electrolyte level is too high, any leak-
age causes damage to the painted surface or corrodes other parts.
q To avoid frozen fluid, add a commercial battery fluid (for the ambient temperature) before you start the next day.
HD465-8, HD605-8 40-47

q When you inspect the electrolyte level through the side face of the battery
1) Clean the battery surface, (especially around the battery level
lines with a clean wet rag. Make sure the battery fluid is
between the UPPER LEVEL (U.L.) and LOWER LEVEL (L.L.)
lines.
kDo not clean the battery with a dry rag. It may generate
an electrical shock, which may cause an explosion.
2) If the electrolyte level is below the LOWER LEVEL lines,

remove cap (1) and add a commercial battery fluid to the
UPPER LEVEL line.
3) After you add the purified water or commercial fluid, tighten the
cap.
NOTICE
If the purified water is added to above the UPPER LEVEL
(U.L.) line, remove the excess. Remove the excess fluid by
using a syringe to lower the level to the UPPER LEVEL
(U.L.) line. Neutralize the removed fluid with the baking
soda (sodium bicarbonate), then flush it aside with a large
quantity of water.
q When you cannot inspect the electrolyte level through the side face of the battery
1) Remove caps (1) from the top of battery. (As described previ-
ously)
2) Look into the fill port (3) and examine the surface of the fluid.
If the fluid level is below the fill guide (4), add purified water (or
commercial battery fluid). Add the fluid until it touches the
bottom of the fill guide rule (the UPPER LEVEL).
q(A) Correct level: When the electrolyte level touches the fill
guide bottom, the shape of the plates will appear twisted be-
cause of the surface tension.
q(B) Low: When the electrolyte level does not touch the fill
guide bottom, the shape of the plates will appear straight.
3) After you add fluid, tighten the cap (1).
NOTICE
If the purified water is added to above the UPPER LEVEL (U.L.) line, remove the excess. Remove the excess
fluid by using a syringe to lower the level to the UPPER LEVEL (U.L.) line. Neutralize the removed fluid with
baking soda (sodium bicarbonate), then flush it aside with a large quantity of water.
Inspection of the wire harness for color changes, heat damage, or weak insulation
6. Examine the wire harness and wire for color changes, heat damage.
k If discolored or heat damaged, examine the circuit for open or short circuit.
q Inspect the wire harness and wires for damage and weak insulation.
q If any problem is found, repair or replace the wiring harness or wire.
40-48 HD465-8, HD605-8

Inspection of the wire harness clamp is secure and the harness is not loose
7. Make sure the wire harness clamp is secure and the harness is not
loose.
REMARK
In particular, carefully inspect around the hot and movable parts. If
clamps are disconnected, connect the harness again.
Inspect for the proper ground

8. Inspect the connection of ground connector
q Make sure that mount bolts and nuts are tight
q Inspect if rust or unwanted materials are attached (to the sur-
faces which touch) on the ground connector (1) and the ma-
chine.
This figure shows the engine ground as an example.
q For the positions of each ground, see "CONNECTORS LIST
AND LAYOUT".
Inspection of a loose connector and a damaged lock

9. Examine the connection of male and female connectors. Pull on
them with your fingers.
10. If the connection is loose, secure it.
11. Make sure the connectors unlock and lock. Inspect the connector
case for cracks.
12. Make sure the lock bolt (2) of the engine controller (1) is tight.
REMARK
Use a 5 mm hex wrench.
HD465-8, HD605-8 40-49

Inspection of connector pins for corrosion, bends and deformation

13. Disconnect the connectors, and examine their pins for corrosion, if bent, lower than other pins, and extension of female
pins.
q If pins are defective, repair or replace them.
q If the pins are not shiny, apply a pin conditioner to them. Then, connect and disconnect the connectors several times
to shine them. (If the pins do not become shiny, connect and disconnect the connectors 10 times)
Inspection of the connector for water and unwanted material

14. Disconnect connectors, and examine them for entry of water or
unwanted material, into the connector.
REMARK
If water or unwanted material is in the connector, the seals are
damaged. Examine the seals for damage.
q If the seal is defective, repair or replace it.

q Dry the inner side of the connector with a dryer.
q Wipe and remove any unwanted material from the inner side
of the connector with a clean rag or brush. Use compressed air
to clean the connector.
Inspection of the wiring harness for open or short circuit

15. Inspect the connection (folded part) between connector pins and wiring harness.
40-50 HD465-8, HD605-8

16. If it is open (shown as A), repair or replace the wiring harness or

wire.
17. Visually examine wiring harness for weak insulation and pins that
touch adjacent pins because of a bad folded area.
Inspection of the fuse for blown out and corrosion

18. If a fuse is corroded with a layer of white matter, or there is any play between the fuse and its case, replace the fuse.
REMARK
q Make sure to turn the battery disconnect switch to OFF before
you replace the fuse.
q A slow-blow fuse is a large capacity fuse.
q Replace each fuse with the same capacity.
q Open battery cover, and fuse (1) and (2) are visible.
q Remove the cover at the rear of the operator's seat to access

the fuse case (BT1) to (BT5).
q See "FUSE LOCATION TABLE".
Inspection of the circuit breaker

19. Inspect the circuit breaker.
REMARK
q Do not push and hold the circuit breaker set switch. (There is a possibility of fire.)
q When there is too much electrical current, the circuit breaker shuts off the electrical circuit. It is used again and again
to prevent damage and broken electrical parts and wires.
1) Turn the start switch to OFF.
HD465-8, HD605-8 40-51

2) Open the battery inspection cover. Examine the circuit

breakers (1) to (4).
3) Push the circuit breaker set switches (1) to (4).
REMARK
qOperation force of the set switch is heavier when the electri-
cal circuit is shut compared to the normal condition.
qThe height of the set switch remains the same although the
condition of the circuit changes from shut to open.
Inspect the alternator volts (when engine speed is moderate or higher)

20. Connect the positive (+) wire of the multimeter to alternator
connector B (E09) and connect the negative (-) wire to the chassis
ground.
21. Start the engine and warm it up. Measure the voltage while you run
the engine at a moderate or higher speed.
q If the voltage is not normal, repair or replace the alternator.
Inspection of the sound of the battery relay operation

22. Open the battery cover.
23. Turn the start switch to ON and OFF. Make sure that the sound of
the battery relay is heard when it operates.
q If the operation sound is not heard, examine the related cir-
cuits. Refer to the procedure to troubleshoot for "ENGINE
DOES NOT START (ENGINE DOES NOT CRANK)" de-
scribed in E mode troubleshooting.
q If the related circuit is normal, replace the battery relay.
NOTICE
Be careful not to mistake the battery relay (1) for the second-
ary steering relay (2).
40-52 HD465-8, HD605-8

40 TROUBLESHOOTING ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION
ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION

q When performing troubleshooting of electric circuits related to machine monitor, transmission controller, retarder and hoist
controller, monitor controller, KOMTRAX terminal, KOMTRAX Plus controller, and engine controller, expose the applicable
connector portion according to the following procedure.
q For connectors whose lock procedure is special, follow the disconnect and connect procedures.
Machine monitor
REMARK
See DISASSEMBLE AND ASSEMBLE, "REMOVE AND INSTALL
MACHINE MONITOR ASSEMBLY".
2. Remove the machine monitor.

3. Disconnect connectors DPC2 and DPC3 from behind the machine
monitor, and connect or put in T-adapters to troubleshoot.
REMARK
Connector DPC1 is used to connect the LCD unit of the machine
monitor to monitor the controller. T-adapter to troubleshoot is not
provided. For details to troubleshoot connector DPC1, see "PREP-
ARATION FOR TROUBLESHOOTING OF MACHINE MONI-
TOR", "PROCEDURES FOR CREATING HARNESS CHECKER
ON MACHINE MONITOR LCD UNIT".
Transmission controller, retarder and hoist controller, monitor controller

1. Remove the auxiliary seat (1).
HD465-8, HD605-8 40-53

ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION 40 TROUBLESHOOTING
2. Disconnect the connectors ATC3 (3), ATC2 (4), and ATC1 (5) of the
transmission controller (2). Engage or connect T-adapter to trouble-
shoot.
3. Disconnect connectors BRC1 (7), BRC2 (8), and BRC3 (9) of

retarder and hoist controller (6). Engage or connect T-adapters to
troubleshoot.
REMARK
q Use a 4 mm hex wrench for the lock screw.
3 Lock screw:
3.0 ±0.2 Nm {0.31 ±0.02 kgm}
q When you put them back, tighten the lock screws to the spec-
ified torque.
4. Disconnect connectors MCM1 (11) and MCM2 (12) of the monitor

controller (10), and connect T-adapters to troubleshoot.
REMARK
q Since the adapter for the monitor controller is not a T-adapter,
the voltage is not measured when you put the adapter into the
connector.
q Connector (13) is used to connect the LCD unit of the machine
monitor. T-adapter to troubleshoot is not provided. For details
to troubleshoot for connector (13), see "PREPARATION FOR
TROUBLESHOOTING OF MACHINE MONITOR", "PROCE-
DURES FOR CREATING HARNESS CHECKER ON MA-
CHINE MONITOR LCD UNIT".
Procedure to disconnect connector MCM1 (11) and MCM2 (12) of
the monitor controller (10).
While you push the lock (L1), turn lock (L2) inward.
REMARK
Bar (B) comes out and the lock is released.
40-54 HD465-8, HD605-8

Refer
q Procedure to remove the connector cover (1)
1. Move lever (3) up.
2. Lightly push the part (A) on the two sides of connector

cover (1) to release hooks (B).
3. Remove the connector cover (1) around hook (C) along the
arc line.
REMARK
Picture shows the connector without its cover (1).
q Procedure to install the connector cover.

1. Push in the right and left slides (4) to the end.
REMARK
Right and left slides (4) pushed in as far as they go (left in
the figure).
HD465-8, HD605-8 40-55

2. Move lever (3) of the connector cover (1) from above to the
left (LOCK condition) in the figure.
q(B), (C): Hooks
qIf the slides and lever are not as shown in the figure, the
connector is neither disconnected nor locked tight with
the lever. Examine them again.
3. Set hook (C) to the connector, and position connector

cover (1).
REMARK
Take care not to become caught in the wiring harness (5).
4. Put in hook (B) to install the connector cover (1).
KOMTRAX controller
40-56 HD465-8, HD605-8

2. Disconnect connectors KOM1A and KOM1B of the KOMTRAX

controller (2), and connect or put in T-adapters to troubleshoot to
them.

1. Open cover (1) at the rear of the operator's seat.
2. Disconnect connectors KPS1 (3) and KPS2 (4) of the KOMTRAX

Plus controller (2), and connect or put in T-adapters to trouble-
shoot them.
ABS controller (Machine with ABS system)

1. Remove the auxiliary seat (1).
HD465-8, HD605-8 40-57

2. Disconnect connectors OPC1 (3), OPC2 (4), and OPC3 (5) of ABS
controller (2), and insert or connect T-adapters for trouble-
shooting.
Middle connector
NOTICE
Water tight seal is attached to the fitting surface of those connectors. Seals shown in the figure are necessary to be
prepared ahead of time when you disconnect the connectors. (This is because the seal may become enlarged or bro-
ken when it is disconnected.)
q 70 Pin
1. Procedure to disconnect the middle connector

1) Slowly remove the connector straight out to look for any crack or other damage in the seal, or stuck unwanted material.
REMARK
If the seal is defective, replace it.
2. Procedure to connect the middle connector
1) Install a seal to the plug.
2) Align the key position to the groove side.
3) Install the connector (the seal is out), use care and push the seal in damage free.
4) Lightly tighten the lock screw in the middle of the connector 2 to 3 turns.
5) Push in the connector completely to the end. Adjust the tilt of the connector to make the clearance between the connec-
tors the same when seen from all directions.
6) Tighten the lock screw to the specified value.
3 Lock screw:
2.8±0.3 Nm {0.28±0.03 kgm}
40-58 HD465-8, HD605-8

Engine controller
REMARK
The engine controller is installed on the engine (left side of the ma-
chine).
2. Connect or put in T-adapters to troubleshoot the connectors J1

and J2 of the engine controller (3).
REMARK
Use a 5 mm hex wrench for the lock screw (2).
3 Lock screw:
9±1 Nm {0.9±0.1 kgm}
3. Disconnect the connector from the engine controller.

The direction of the engine controller differs with the machine.
1) Hold the connector lever (1) as shown in the figure and put the
point of your thumb to the connector.
2) Support the connector with your thumb, raise your arm a small
amount and release the lock.
3) Unlock the connector lever (1) completely, and then discon-

nect the connector.
HD465-8, HD605-8 40-59

4. Connect the connector as you refer to the procedure.

1) Install the connector straight to the engine controller with lever (1) completely unlocked.
2) Lower lever (1) to the initial position, and then push it to lock
the connector. (Make sure by sound and feel.)
REMARK
Tighten the connector lock bolt to the shown value.
3 Connector lock bolt:
9±1 Nm {0.9±0.1 kgm}
Connectors related to engine

q FRAMATOME connector
Ambient pressure sensor (PAMB)
Engine NE speed sensor (NE)
Crankcase pressure sensor (PCCV)
Engine oil pressure sensor (POIL)
Charge (Boost) pressure sensor (PIM)
Fuel dosing pressure sensor (AFT1_PFUEL, AFT2_PFUEL)
Mass air flow and temperature sensor (MAF)
Shut off valve solenoid #1 (AFT1_SOV1, AFT2_SOV1)
Shut off valve solenoid #2 (AFT1_SOV2, AFT2_SOV2)
Fuel dosing solenoid (AFT1_HC_INJ, AFT2_HC_INJ)
KDPF differential pressure and Output pressure sensor (DPFP1, DPFP2)
q Disconnect and connect the connectors
Disconnect the connectors in the sequence of (a) to (c), and
connect them in the sequence of (d) to (f) as shown in the fig-
ure.
Disconnect: (a) Slide the lever, (b) unlock, and (c) disconnect
the connectors.
Connect: (d) Connect the connectors, (e) engage the lock, and
(f) slide the lever.
q SUMITOMO connector
q Bkup (camshaft) speed sensor (P1_G, P2_G)
Supply pump PCV1 (P1_PCV1, P2_PCV1)
Supply pump PCV2 (P1_PCV2, P2_PCV2)
q Disconnect and connect of connectors
Disconnect the connectors in the sequence of (a) to (b), and
connect them in the sequence of (c) to (d) as shown in the fig-
ure.
Disconnect: (a) Unlock and (b) disconnect the connectors.
Connect: (c) Connect the connectors and (d) engage the lock.
40-60 HD465-8, HD605-8

q AMP connector
q Common rail pressure sensor (PFUEL)
ure.
q Precautions to disconnect the connectors
The direction of the lock for the connector is changes, to the
bottom or side of the engine. To unlock, it depends on the po-
sition the sensor is installed.
Take hold of the lock in the direction (a). Use needle-nose pli-
ers [1] with point made into a curve to easily open the lock.
Since the lock clicks when it is opened, listen for the sound
and disconnect the connectors.
q Precautions to connect connectors
When you connect connectors, do not connect them turned
180°.
q PACKARD connector
q Engine coolant temperature sensor (TWTR)
Charge (Boost) temperature sensor (TIM)
ure.
q Removal and installation of sensor body
A deep socket is necessary to remove and install the coolant
temperature sensor. Refer to TEST AND ADJUST, "DIAGRAM FOR TEST AND ADJUST TOOLS".
q TYCO connector
REMARK
The connector is used in the sensors which transmit information to the engine controller through the CAN communication
system.
q KDPF temperature sensor (DPFT1, DPFT2)
HD465-8, HD605-8 40-61

q Procedure to disconnect connectors

1. Engage small flat-head screwdriver [1] to the yellow lock
piece (2) of the TYCO connector (1).
2. Turn the small flat-head screwdriver [1] right and left, and
slowly release the lock piece (2).
3. When the yellow lock piece (2) is partly released, lightly

hold the lock piece (2), and release the lock completely.
REMARK
To keep the the yellow lock part (2) on, do not apply extra
force when you release the lock.
4. Remove the connector (1) when the lock piece (2) is

completely released.
40-62 HD465-8, HD605-8

q Procedure to connect connectors

1. Install the connector (1) straight as you match the faces to
be engaged when the yellow lock piece (2) is completely
released.
2. Install the connector (1) gradually as you push the yellow

lock piece (2).
HD465-8, HD605-8 40-63

PROCEDURE FOR TESTING AND TROUBLESHOOTING 40 TROUBLESHOOTING
PROCEDURE FOR TESTING AND TROUBLESHOOTING

Type to troubleshoot
Mode Content
Display of code Troubleshoot by failure code
E mode Troubleshoot the electrical system
H mode Troubleshoot the hydraulic and mechanical systems
S mode Troubleshoot the engine
If a symptom which is assumed to be a failure occurs on the machine, go to the corresponding troubleshooting section.
q Action level and failure code are shown on the standard screen of the machine monitor. Troubleshoot the corresponding
[Display of code] corresponding to the shown failure code.
REMARK
If more than one failure code is shown at the same time, all the codes are shown again and again in sequence. Write down
all the codes.
q Action level and failure code are not shown on the standard screen of the machine monitor. Examine the mechanical sys-
tem failure code and electrical system failure code with the Abnormality Record function of the machine monitor.
q If a failure code is shown, troubleshoot for the corresponding [Display of code] corresponding to the failure code.
q If an electrical system failure code is shown, delete all the codes once and repeat them, and then see if the failure stays
sensed.
REMARK
A failure code of the mechanical system is not possible to delete.
q No failure code is found in the Abnormality Record. A failure that the machine cannot find by itself may occur in the electrical
system, or hydraulic and mechanical system.
Examine a symptom which is assumed to be a failure again and select the same reason from the table of Symptoms and
troubleshoot numbers. Then troubleshoot the failure in [E mode], [H mode] or [S mode].
After the repair is completed, delete all the failure codes in the Electrical System Abnormality Record. Refer to these proce-
dures.
1. Push and hold the DOWN switch (6) on the switch plate at the standard screen. Then, (with switch (6) down) push number
keys [1]→[2]→[3] in sequence, the "Service Menu" screen appears.
q (4) is the ENTER switch/ (check mark).
q (5) is the RETURN switch/.
q (7) is the MENU switch/ (to delete all).
2. On "Service Menu" screen, push DOWN switch (6) twice in the
switch plate section, and select "03 Abnormality Record".
40-64 HD465-8, HD605-8

40 TROUBLESHOOTING PROCEDURE FOR TESTING AND TROUBLESHOOTING
3. Push the ENTER switch (4) in the switch plate section to enter the
selection, and go to the "Abnormality Record" screen.
4. Push the ENTER switch (4) in the switch plate section to enter the
selection, and go to the "Mechanical Sys Abnormality Record"
screen.
5. If the next failure code is shown, move down, push the DOWN
switch (6) on the switch plate to see. Write down all of the failure
codes.
REMARK
A failure code of the mechanical system is not possible to delete.
6. Push the BACK switch (5) in the switch plate section to go back to
the "Abnormality Record" screen.
7. Go to the "Electrical Sys Abnormality Record" screen like steps 2

and 3.
8. Push the DOWN switch (6) on the switch plate to see if the next
failure code is shown and note down all of the failure codes.
REMARK
"E" on the left of a failure code indicates that the failure code is "In
operation". The failure remains or is not corrected to normal. A fail-
ure code having no "E" on its left is a "Non-active" one. Since it dis-
appears at the following clear step, be sure to write it down.
9. While you push DOWN switch (6) on the switch plate, push
number keys [1]→[2]→[3] in the sequence to go to the "Clear
mode". (Same as 1)
10. Push the MENU switch (7) (CLEAR) on the switch plate.
11. Push the ENTER switch (4) on the switch plate to delete all failure
codes.
12. Push the RETURN switch (5) in the switch plate section to go back
to the "Electrical Sys Abnormality Record" screen. Write down any
failure codes which continue to show.
13. Push the BACK switch (5) in the switch plate section to go back to
the "Abnormality Record" screen.
HD465-8, HD605-8 40-65

SYMPTOM AND TROUBLESHOOTING NUMBERS 40 TROUBLESHOOTING
SYMPTOM AND TROUBLESHOOTING NUMBERS

Troubleshoot
No. Symptom of failure
Index
Operator code, failure code
Action level is shown on the machine monitor. Push the enter switch (checkmark) to
1
show the "Present Abnormality".
Troubleshoot for the failure
2 Failure code is shown on "Mechanical Sys Abnormality Record". code.
3 Failure code is shown on "Electrical Sys Abnormality Record".
Symptom related to engine
4 Engine does not start (engine does not crank). E-1
5 Engine does not crank when starting switch is turned to start position. S-1
6 Engine cranks but no exhaust gas comes out. S-2
Fuel is being injected but engine does not start (misfiring: engine cranks but does
7 S-3
not start)
8 Engine startability is poor. S-4
9 Engine does not pick up smoothly. S-5
10 Engine stops during operation. S-6
11 Engine runs rough or is unstable. S-7
12 Engine lacks force. S-8
13 KDPF gets clogged in a short time. S-9
14 Engine oil consumption is excessive. S-10
15 Oil becomes contaminated quickly. S-11
16 Fuel consumption is excessive. S-12
17 Oil is in coolant (or coolant spurts back or coolant level goes down). S-13
18 Oil pressure drops. S-14
19 Fuel mixes into engine oil. S-15
20 Water mixes into engine oil (appears white). S-16
21 Coolant temperature rises too high (overheating). S-17
22 Unusual noise is heard. S-18
23 Vibration is excessive. S-19
24 Air cannot be bled from fuel circuit. S-20
25 In operation regeneration is executed frequently. S-21
26 In operation regeneration takes time. S-22
27 White smoke is exhausted during active regeneration. S-23
40-66 HD465-8, HD605-8

40 TROUBLESHOOTING SYMPTOM AND TROUBLESHOOTING NUMBERS
Troubleshoot
Index
28 Manual preheating system does not work. E-2
29 Automatic preheating system does not work. E-3
30 While preheating is working, preheating monitor does not light up. E-4
31 AISS function does not operate properly. E-28
32 Fuel feed pump does not operate or does not stop automatically. E-30
Symptom related to travel
33 Machine does not start. H-1
34 Machine does not travel smoothly (machine hunts). H-2
35 Lockup is not released. H-3
36 Abnormally large shocks result from starting of machine and gear shifting. H-4
37 Gear is not shifted up. H-5
Machine lacks travel speed or power when traveling in lockup drive mode at all gear
38 H-6
speeds.
39 Machine lacks travel speed or power when traveling in torque converter drive mode. H-7
40 Machine lacks travel speed or power when traveling at some gear speed. H-8
41 Large time lag is observed when machine starts and gear is shifted. H-9
42 Oil temperature of the torque converter is high. H-10
43 Oil pressure of torque converter is low. H-11
44 Steering wheel is heavy to operate. H-12
45 Steering wheel cannot be operated. H-13
46 Steering wheel waggles. H-14
Symptom related to the work equipment
47 Hoist lever does not operate properly. E-29
48 Dump body rising speed is low. H-17
49 Hydraulic drift of dump body is large. H-18
50 Dump body does not move. H-19
Brake component
51 Front brake does not work enough. H-15
52 Rear brake does not work enough. H-16
Symptom related to fan
53 Fan speed is abnormal (too high or low, or stationary). H-20
54 Unusual noise is heard from around fan. H-21
HD465-8, HD605-8 40-67

SYMPTOM AND TROUBLESHOOTING NUMBERS 40 TROUBLESHOOTING
Troubleshoot
Index
Symptom related to the machine monitor
55 All of LCD unit, LED unit, and meter unit on machine monitor display nothing. E-5
56 LCD unit on machine monitor displays nothing. E-6, E-7
Backlight of LCD unit on machine monitor is abnormal, (backlight goes out or flick-
57 E-8
ers)
58 LCD on machine monitor does not display properly. E-9
59 Meter unit display on machine monitor is abnormal. E-10
60 Night lighting lamp of meter unit on machine monitor is abnormal. E-11
61 LED unit lamp on machine monitor is abnormal. E-12
Night lighting lamp of switch panel on machine monitor is abnormal or switch does
62 E-13
not operate properly.
63 2 switches operation of switch panel on machine monitor does not function. E-14
64 Switch plate buzzer of the machine monitor is unusual. E-15
Some items of gauges and caution lamps on the machine monitor are not shown
65 E-16
correctly.
66 Rearview monitor does not light up or back light flickers. E-17
67 Rearview monitor images are not displayed clearly. E-18
68 Rearview monitor brightness cannot be adjusted. E-19
69 Night lighting lamp of rearview monitor is abnormal. E-20
Rearview monitor does not display images while reverse linked display function is
70 E-21
enabled.
71 Guide line on rearview monitor is not displayed while guide line is set. E-22
72 Fuel level gauge does not indicate the correct level. E-23
73 Seat belt caution lamp indication is abnormal. E-24
74 Machine monitor cannot be operated when starting switch is in OFF position. E-25
75 Alarm buzzer does not sound. E-26
76 Alarm buzzer does not stop sounding. E-27
PROCEDURE TO TEST
Air conditioner does not operate correctly (also failure codes related to the air condi-
77 AND TROUBLESHOOT in
tioner).
Chapter 80
Others
78 Turn signal lamp and winker lamp (hazard lamp) do not operate properly. E-31
79 None of headlamp, clearance lamp, and tail lamp lights. E-32
80 Small lamp (clearance lamp) does not light up. E-33
40-68 HD465-8, HD605-8

40 TROUBLESHOOTING SYMPTOM AND TROUBLESHOOTING NUMBERS
Troubleshoot
Index
81 Tail lamp does not light up. E-34
82 (Low beam) head lamp does not light up. E-35
83 (High beam) head lamp does not light up. E-36
84 Neither (low beam) nor (high beam) head lamps lights up. E-37
85 High beams do not light up while passing switch is operated. E-38
86 KOMTRAX system does not operate normally. E-39
87 Data downloading by using wireless LAN can not be performed. E-40
HD465-8, HD605-8 40-69

INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 40 TROUBLESHOOTING
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE

(Rev.2011/12)
These types of information are described in the table to troubleshoot and related circuit diagram. Fully understand the informa-
tion described and troubleshoot.
Action level Failure code

Failure name shown on the "Abnormality Record" screen of the machine
Display on Display on Failure
monitor
the machine the machine
monitor monitor
Details of fail-
Report of the failure found by the machine monitor or controller
ure
Procedure of A procedure that is performed to protect the system and devices when the monitor or controller finds a
controller machine failure.
Event on A problem shown as a failure on the lift truck as a result of a procedure (above) performed by the machine
machine monitor or controller.
Related infor-
Information related to the occurred failure and its troubleshooting
mation
40-70 HD465-8, HD605-8

40 TROUBLESHOOTING INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE
No. Cause Procedure, measuring location, criteria, and remarks
1 Defective --- Contents of report

q Procedure
Open or short q Measure point
2 circuit in wiring
harness "Between A and B" denotes measuring values such as voltage and resistance, etc. between A
and B.
Open circuit in Ground of "Between A and ground" means the measurement of voltage, resistance or others
wiring harness
between place A and the place which has a continuity with chassis frame such as unpainted
3 (Wire broken or
defective touch hexagonal head bolt or bolt hole which has no rust, etc.
with connector) "Between A and each pin other than pin A" of continuity test items means the measurement of
continuity between pin A and each pin other than pin A.
Ground fault in
wiring harness REMARK
4
(touch to
Use the continuity range of the meter to measure. It is easier to measure and make sure with
ground circuit)
sound.
Hot short cir- q Standard to judge probable causes, notes
5
cuit How to use the troubleshoot sheet
q Perform procedures to troubleshoot, follow this sequence.
q If the check result does not meet the standard, the probable cause described on the left is the
real cause of the failure.
q If the check result meets the standard and there is no specified instruction, proceed to the next
step (cause).
q If damage is found and repaired, make sure that the damage is corrected.
Failures in wiring harness
q Open circuit
When the wires and the internal circuit of the connector are not connected with each other,
Short circuit in
6 there is no continuity
wiring harness
q Ground fault
A wiring harness not to be connected to the GND (ground) circuit comes to touch with the GND
(ground) circuit or chassis.
q Hot short circuit
A wiring harness not to be connected to the power circuit touches the power circuit accidentally.
q Short circuit
A wire in the harness abnormally touches with another wire. (Defective insulation in connector
or others)
Precautions when you troubleshoot

(1) Connector number indication and handling of T-adapter
To troubleshoot, position or connect T-adapters as follows unless otherwise indicated.
q When (male) or (female) is not indicated with a connector number, disconnect the connector,
and put T-adapters into the two sides (male and female).
q When (male) or (female) is indicated with a connector number, disconnect the connector, and
connect T-adapter to the indicated side of connector.
Defective con-
7 q "Male and female" indicates male and female of connector pins, not connector cases.
troller
q Male and female of connector pins and cases in DT connectors, are opposite to those de-
scribed in this manual. Take care.
(2) Pin number description sequence and meter connections.
To troubleshoot, connect the positive (+) and negative (-) of a meter as shown below unless oth-
erwise indicated.
q Connect the positive (+) wire to the pin or wiring harness indicated in the front.
q Connect the negative (-) wire to the pin or wiring harness indicated in the rear.
HD465-8, HD605-8 40-71

INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 40 TROUBLESHOOTING
Related circuit diagram
This is the portion of the circuit diagram related to the troubleshoot

q The circuit diagram contains the connector No., pin No., and connector color related to the failure.
q / is used in the connector No. in these 2 cases.
q Abbreviation (3 characters in many cases)
Example T/C: Abbreviation for Torque Converter
q Male side and female side have different connector numbers.
Example) BREAK OUT / E24
q The circuit diagram contains the destination or source of the secondary circuit in a wiring harness.
q Arrow (↔): Approximate installation position on the machine
NO: Normally Open
NC: Normally Closed
q Signal names such as GND and 24 V are included in addition to connector numbers at connections in circuit diagrams.
q Except for GND and 24 V, a signal name indicated at a connection shows that the wire is connected to another connection
or controller. The same signal name is used at the other connection or controller.
40-72 HD465-8, HD605-8

40 TROUBLESHOOTING CONNECTORS LIST AND LAYOUT
CONNECTORS LIST AND LAYOUT

Number
Connector No. Connector type Location Address
of pins
1,PS DT 2 Solenoid (1st) AI-9
1,SW DT 2 Fill switch (1st) AI-9
2,PS DT 2 Solenoid (2nd) AI-9
2,SW DT 2 Fill switch (2nd) AI-9
3,PS DT 2 Solenoid (3rd) AH-9
3,SW DT 2 Fill switch (3rd) AH-9
4,PS DT 2 Solenoid (4th) AG-9
4,SW DT 2 Fill switch (4th) AG-9
53- Terminal 1 Secondary steering relay C-9
54+ Terminal 1 Secondary steering relay C-8
55- Terminal 1 Secondary steering relay C-8
56+ Terminal 1 Secondary steering relay B-8
58- Terminal 1 Battery relay B-8
59+ Terminal 1 Battery relay A-8
60- Terminal 1 Battery relay A-8
61+ Terminal 1 Battery relay A-8
62 Terminal 1 Circuit breaker (105A) A-2
70 Terminal 1 Secondary steering relay C-9
71 Terminal 1 Secondary steering relay C-9
72 Terminal 1 Secondary steering relay B-9
73 Terminal 1 Secondary steering relay B-9
74 Terminal 1 Battery relay A-9
75 Terminal 1 Battery relay A-9
76 Terminal 1 Battery relay B-9
77 Terminal 1 Battery relay B-9
81 Terminal 1 Slow-blow fuse B-1
83 Terminal 1 Slow-blow fuse B-1
Transmission electrical system temporary recovery
A1 X 1 S-9
switch
AATS 090 2 Air conditioner fresh air temperature sensor D-2
ABSFL DT 2 ABS control valve (front left) (if equipped) AZ-9
HD465-8, HD605-8 40-73

CONNECTORS LIST AND LAYOUT 40 TROUBLESHOOTING
Number
of pins
ABSFR DT 2 ABS control valve (front right) (if equipped) AW-9
ABSP EJ2 3 ABS cut valve pressure sensor (if equipped) BB-4
ABSRL DT 2 ABS control valve (rear left) (if equipped) BB-7
ABSRR DT 2 ABS control valve (rear right) (if equipped) BB-5
AC DT 2 Air conditioner compressor C-2
AC1 YAZAKI 10 Air conditioner unit U-9
AC2 SUMITOMO 4 Air conditioner unit U-9
ACC Terminal 1 Starting switch terminal ACC N-1
ACCF EJ2 3 Accumulator oil pressure sensor (front) J-2
ACCR EJ2 3 Accumulator oil pressure sensor (rear) J-3
ACECU SUMITOMO 32 Air conditioning controller -
ACS YAZAKI 2 Accessory socket T-9
ADDH DT 2 Added heater (if equipped) S-1
AFT1_HC_INJ FRAMATOME 2 Fuel doser-A AN-6
AFT1_PFUEL FRAMATOME 3 Dosing fuel pressure sensor-A AL-9
AFT1_SOV1 FRAMATOME 2 Fuel doser solenoid valve 1-A AK-9
AFT1_SOV2 FRAMATOME 2 Fuel doser solenoid valve 2-A AL-9
AFT2_HC_INJ FRAMATOME 2 Fuel doser-B AN-5
AFT2_PFUEL FRAMATOME 3 Dosing fuel pressure sensor-B AN-9
AFT2_SOV1 FRAMATOME 2 Fuel doser solenoid valve 1-B AN-9
AFT2_SOV2 FRAMATOME 2 Fuel doser solenoid valve 2-B AM-9
AGP DT 6 Middle connector (automatic lubricant tank) E-9
AGS X 4 Automatic lubricant switch (if equipped) M-1
AISS SWP 6 AISS switch O-2
ARC M 3 Automatic retarder speed control set switch P-2
AS1 DT 6 Acceleration sensor O-1
AS2 DT 2 Acceleration sensor P-1
AS3 DT 3 Middle connector M-7
ASS DT 2 Air suspension seat U-1
ATC1 DRC26 24 Transmission controller P-7
ATC2 DRC26 40 Transmission controller P-7
ATC3 DRC26 40 Transmission controller Q-8
ATF HD30 31 Middle connector H-2
AUX DT 12 External supply communication connector X-6
B Terminal 1 Start switch connector B O-1
B04 DT 2 Backup lamp L-9
B05 Terminal 1 Backup alarm buzzer K-9
B06 Terminal 1 Backup alarm buzzer K-9
40-74 HD465-8, HD605-8

Number
of pins
B07 DT 3 Dump body position sensor J-9
B08 DT 2 Added backup lamp (if equipped) K-9
B10 Terminal 1 Ground (frame) L-8
B1L DT 2 Payload meter green indicator lamp (L.H.) L-1
B1R DT 2 Payload meter green indicator lamp (R.H.) C-8
B2L DT 2 Payload meter orange indicator lamp (L.H.) L-1
B2R DT 2 Payload meter orange indicator lamp (R.H.) C-8
B3L DT 2 Payload meter red indicator lamp (L.H.) L-2
B3R DT 2 Payload meter red indicator lamp (R.H.) C-8
BCF DT 2 Brake cool filter switch (if equipped) -
BCVR2 DT 2 BCV solenoid I-9
BK DT 12 Middle connector L-5
BL SWP 6 Revolving lamp switch (if equipped) R-9
ABS control valve pressure sensor (front left) (if
BPFL DT 3 AX-9
equipped)
ABS control valve pressure sensor (front right) (if
BPFR DT 3 AY-9
equipped)
ABS control valve pressure sensor (rear left) (if
BPRL DT 3 BB-8
equipped)
ABS control valve pressure sensor (rear right) (if
BPRR DT 3 BA-8
equipped)
BR Terminal 1 Start switch connector BR N-1
BRC1 DRC26 24 Retarder and hoist controller P-6
BRC2 DRC26 40 Retarder and hoist controller O-6
BRC3 DRC26 40 Retarder and hoist controller O-6
BT DT 8 Middle connector A-1
BT-1A Terminal 1 Battery A-9
BT-1B Terminal 1 Battery A-9
BT-2A Terminal 1 Battery A-9
BT-2B Terminal 1 Battery A-9
BT1 Terminal 30 Fuse case S-9
BT5 Terminal 30 Fuse case T-9
BZ2 M 2 Buzzer R-1
C Terminal 1 Start switch connector C O-1
CAB2 SWP 8 Middle connector M-4
CCR SUMITOMO 5 Air conditioner compressor clutch relay U-9
CEN11_RES DT 3 Termination resistor 120 Ω AN-1
HD465-8, HD605-8 40-75

Number
of pins
CEN12_RES DT 3 Termination resistor 120 Ω AM-1
CEN21_RES DT 3 Termination resistor 120 Ω AL-2
CEN22_RES DT 3 Termination resistor 120 Ω AL-2
CGG D08032 1 Cigarette lighter P-6
CGP D08032 1 Cigarette lighter P-7
CJ2 DT 6 Joint connector J-2
CJ3 DT 8 Joint connector K-3
CJ4 DT 6 Joint connector L-3
CJ5 DT 6 Joint connector J-2
CJ6 DT 8 Joint connector B-6
CJA DT 6 Joint connector C-8
CJB DT 4 Joint connector K-3
CJC DT 4 Joint connector J-3
CJD DT 8 Joint connector D-8
CJE DT 6 Joint connector B-7
CJF DT 6 Joint connector B-7
CJG DT 6 Joint connector F-9
CJH DT 6 Joint connector B-6
CJJ DT 6 Joint connector C-7
CJK DT 4 Joint connector B-5
CJL DT 8 Joint connector B-5
CJN DT 4 Joint connector (if equipped) B-3
CJN DT 4 Joint connector (if equipped) BJ-2
CJN1 DT 6 Joint connector D-9
CJN2 DT 4 Joint connector D-9
CJP DT 8 Joint connector F-1
CJQ DT 4 Joint connector F-1
CJR DT 6 Joint connector B-1
CJS DT 6 Joint connector G-1
CJT DT 6 Joint connector J-1
CJU DT 6 Joint connector K-8
CJV DT 4 Joint connector K-8
CJW DT 6 Joint connector K-8
CJX DT 6 Joint connector K-8
CJY DT 6 Joint connector K-8
CM DT 8 Light switch Q-2
CN1 DT 2 Injector AN-5
CN2 DT 2 Injector AO-5
40-76 HD465-8, HD605-8

Number
of pins
CN3 DT 2 Injector AO-5
CN4 DT 2 Injector AP-5
CVF DT 2 ABS cut valve (front) (if equipped) AR-8
CVR DT 2 ABS cut valve (rear) (if equipped) BA-8
CVSF DT 3 ABS cut valve pressure switch (front) (if equipped) AT-9
CVSR DT 3 ABS cut valve pressure switch (rear) (if equipped) BB-6
D01 DT 2 Diode X-6
D02 DT 2 Diode X-6
D03 DT 2 Diode F-9
D04 DT 2 Diode M-6
D05 DT 2 Diode B-7
D06 DT 2 Diode M-6
D07 DT 2 Diode M-6
D09 DT 2 Diode X-6
D10 DT 2 Diode M-6
D11 DT 2 Diode J-2
D12 DT 2 Diode X-6
D15 DT 2 Diode L-2
D16 DT 2 Diode M-6
D17 DT 2 Diode X-6
DC1 Terminal 1 Battery disconnect switch C-9
DC2 Terminal 1 Battery disconnect switch C-8
DC3 Terminal 1 Battery disconnect switch (if equipped) -
DC4 Terminal 1 Battery disconnect switch (if equipped) -
DCC DT 6 DC/DC converter M-8
DEFR Relay 4 Heated wire window relay (if equipped) O-6
DFSW SWP 6 Heated wire glass switch (if equipped) R-9
DL DT 12 Service connector V-8
DL2 RJ45 8 Service connector V-8
DLK1 DT 3 Smart sensor terminating resistor G-9
DLK2 DT 3 Smart sensor terminating resistor G-9
DLSW Terminal 1 Wake-up switch C-2
DPC1 MX4008 8 Monitor display O-2
DPC2 AMP070 6 Monitor display O-2
DPC3 AMP070 8 Monitor display O-2
DPFP1 FRAMATOME 4 KDPF pressure sensor F-9
HD465-8, HD605-8 40-77

Number
of pins
DPFP2 FRAMATOME 4 KDPF pressure sensor H-9
DPFT1 TYCO 4 KDPF temperature sensor G-9
DPFT2 TYCO 4 KDPF temperature sensor H-9
DSL M 1 Door switch (L.H.) AD-6
DSOL X 2 Door solenoid O-6
DSR M 1 Door switch (R.H.) Y-7
DTL SWP 6 Daytime lighting ON switch R-1
E Terminal 1 Secondary steering motor J-1
E01 Terminal 1 Alternator (terminal R) B-3
E02A DT 2 Starting motor safety relay B-6
E02B DT 2 Starting motor safety relay B-6
E04 DT 2 Engine oil level switch E-1
E06 Terminal 1 Alternator (terminal E) B-2
E09 Terminal 1 Alternator B-2
E11B Terminal 1 Intake air heater relay B-2
E14 Terminal 1 Starting motor B-7
E15 Terminal 1 Starting motor B-7
E17B DT 2 Diode B-2
E80 Terminal 1 Ground (frame) F-9
ECM1 J1 DELPHI 96 Engine controller AN-1
ECM1 J2 DELPHI 96 Engine controller AO-1
ECM2 J1 DELPHI 96 Engine controller AL-2
ECM2 J2 DELPHI 96 Engine controller AM-1
EG DT 8 Middle connector H-1
EGL DT 2 Engine section lamp (if equipped) G-1
EGR_SOL DT 2 EGR valve solenoid AL-4
EGS DT 2 Middle connector C-2
EMPR D08027 2 Secondary steering fuse A-1
EPA DT 2 Fuel feed pump B-7
EPB DT 2 Fuel feed pump D-1
EPTS DT 12 Fuel feed pump timer switch G-1
ER1 Terminal 1 Ground (frame) B-8
ER1 Terminal 1 Ground (frame) T-1
ER2 Terminal 1 Ground (frame) B-8
ER3 Terminal 1 Ground (frame) E-9
ER3 Terminal 1 Ground (frame) T-1
40-78 HD465-8, HD605-8

Number
of pins
ER4 Terminal 1 Ground (frame) F-9
ER5 Terminal 1 Ground (frame) E-9
ER6 Terminal 1 Ground (main frame) AJ-3
ER8 Terminal 1 Ground (frame) J-1
ER10 Terminal 1 Ground (engine) G-1
ESS SWP 6 Engine shutdown secondary switch Q-8
ESS SWP 6 Middle connector BV-9
ESS_F SWP 6 Middle connector (if equipped) BR-7
ESS_M SWP 6 Middle connector (if equipped) BX-8
ESS2 Terminal 1 Emergency engine stop switch (if equipped) BM-1
ESS3 Terminal 1 Emergency engine stop switch (if equipped) BN-1
ESS4 Terminal 1 Emergency engine stop switch (if equipped) BT-1
ESS5 Terminal 1 Emergency engine stop switch (if equipped) BS-1
ESS6 Terminal 1 Emergency engine stop switch (if equipped) BJ-5
ESS7 Terminal 1 Emergency engine stop switch (if equipped) BJ-4
EST DT 6 Middle connector M-1
ESW1 Terminal 1 Engine section lamp switch (if equipped) -
ESW2 Terminal 1 Engine section lamp switch (if equipped) -
ETL RJ45 8 Receive the data connector (if equipped) -
FBC SWP 6 Front brake cut switch O-2
FL02 DT 2 Radiator coolant level switch B-5
FL04 D08027 2 Washer motor D-8
FLS D08027 4 Flasher Q-1
FLT DT 4 Middle connector L-2
FOG SWP 6 Fog lamp switch (if equipped) P-3
FR01 DT 2 Air cleaner blockage sensor C-8
FUEL1 DT 2 Middle connector L-7
FUEL2 DT 2 Fuel gauge sensor H-9
GND Terminal 1 Ground (frame) C-8
GR1 Terminal 1 Wake-up switch C-2
H Terminal 1 Intake air heater B-4
H,PS DT 2 Solenoid (Hi) AF-9
H,SW DT 2 Fill switch (Hi) AF-9
H01 DT 3 Steering pressure sensor K-3
H02 DT 3 Secondary steering pressure sensor L-1
HAZ SWP 6 Hazard switch O-2
HEPC DT 2 Hoist EPC valve J-2
HG DT 2 Heat wire window (if equipped) M-3
HD465-8, HD605-8 40-79

Number
of pins
HLS SUMITOMO 2 Air conditioner gas pressure switch B-4
HM21A DT 2 Exhaust temperature sensor B-7
HM22A DT 2 Middle connector X-5
HM23A DT 3 Exhaust gas temperature sensor amplifier W-7
HM55 DT 3 Protocol connector V-8
HML DT 2 Middle connector L-1
HMR Relay 4 Heated wire mirror relay (if equipped) N-6
HMR1 DT 2 Heated wire mirror (if equipped) -
HMR2 DT 2 Heated wire mirror (if equipped) -
HMS SWP 6 Heated wire mirror switch (if equipped) R-9
HN DT 4 Middle connector B-4
HN DT 2 Horn switch P-2
HN1 90 2 Horn valve (Lo) B-4
HN2 90 2 Horn valve (Hi) B-4
HSL DT 4 Hoist lever potentiometer U-1
HSOL DT 3 Hoist selector valve J-2
HTA DT 12 Middle connector K-3
HTB DT 12 Middle connector J-3
HTC DT 12 Middle connector J-1
HTR HD30 23 Middle connector -
IDJ DT 8 Middle connector M-1
ILK DT 2 Idle stop O-6
INJ DT 12 Middle connector AP-3
J01 HD30 9 Middle connector X-3
J02 DTHD 1 Middle connector X-3
J03 DTHD 1 Middle connector W-3
J04 DTHD 1 Middle connector W-2
J05 DTHD 1 Middle connector V-2
J06 DRC16 70 Middle connector X-4
J10 DRC16 24 Middle connector W-2
J11 RJ45 8 Middle connector V-2
J13 DTHD 1 Middle connector V-2
J14 DT 8 Middle connector V-2
J15 DRC16 70 Intermediate connector (if equipped) BH-7
J31A DT 8 Middle connector G-9
40-80 HD465-8, HD605-8

Number
of pins
J31B DT 8 Middle connector G-9
JABS1 DT 6 Joint connector (if equipped) AR-4
JABS2 DT 4 Joint connector (if equipped) AU-1
JABS4 DT 6 Joint connector (if equipped) AR-3
JC01 DT 8 Joint connector AK-6
JC02 DT 9 Joint connector AO-8
JC04 DT 8 Joint connector AP-2
JC05 DT 8 Joint connector AP-3
JC06 DT 12 Joint connector AL-5
JCA SWP 16 Joint connector W-9
JCC SWP 16 Joint connector M-4
JCE SWP 16 Joint connector M-5
JCG DT 8 Joint connector V-8
JCH DT 8 Joint connector U-9
JM01 - 3 Joint connector -
JPS DT 12 Intermediate connector K-3
JS - 2 Jump-start (if equipped) -
KOM/c_RES1 DT 3 Termination resistor 120 Ω AM-1
KOM/r DT 3 Resistor AL-3
KOM/r _RES DT 3 Termination resistor 120 Ω AL-3
KOM1A AMP070 18 KOMTRAX terminal Q-1
KOM1B AMP070 12 KOMTRAX terminal P-1
KPS1 DRC26 50 KOMTRAX Plus controller W-7
KPS2 DRC26 50 KOMTRAX Plus controller X-7
KPS4 RJ45 8 KOMTRAX Plus controller W-7
KPS5 RJ45 8 KOMTRAX Plus controller X-7
L,PS DT 2 Solenoid (Lo) AG-9
L,SW DT 2 Fill switch (Lo) AG-9
L/U,PS DT 2 Torque converter lockup solenoid AG-9
HD465-8, HD605-8 40-81

Number
of pins
LKO DT 2 Lever kick-out solenoid U-1
LL1 DT 2 Middle connector F-1
LL2 DT 2 Ladder lamp (if equipped) -
LLS SWP 6 Ladder lamp switch (if equipped) R-1
LLS2 DT 3 Middle connector C-2
LLSW1 Terminal 1 Ladder lamp switch (if equipped) -
LM1 Terminal 1 Indicator lamp D-1
LM2 Terminal 1 Indicator lamp D-1
LP1 DT 8 Middle connector E-1
M Terminal 1 Secondary steering motor K-1
Main relief oil pressure selector valve oil pressure sen-
M/P,P EJ2 3 AE-3
sor
M/P,PS DT 2 Main relief oil pressure selector valve AE-2
M01A - 3 Radio R-1
M01B M 3 Middle connector M-9
M01C - 3 Stereo jack T-9
MAF FRAMATOME 4 Mass air flow sensor D-8
MCM1 AMP 81 Monitor controller O-6
MCM2 AMP 40 Monitor controller N-5
MCM3 MX4008 8 Monitor controller N-5
ML0 DT 8 Middle connector H-2
ML01 DT 4 Middle connector B-3
ML01 DT 6 Middle connector BJ-2
MLL DT 2 Machine lockout work lamp (if equipped) B-3
MLL DT 2 Machine lockout work lamp (if equipped) BJ-4
MLS SWP 6 Machine lockout switch (if equipped) B-3
MLS SWP 6 Machine lockout switch (if equipped) BJ-3
N1 DT 2 Input shaft speed sensor AE-5
N2 DT 2 Middle shaft speed sensor AE-4
N3 DT 2 Output shaft speed sensor AJ-6
NE FRAMATOME 3 NE speed sensor AP-1
OPC1 DRC26 24 ABS controller (if equipped) BC-6
OPC4 DT 12 Middle connector S-1
OPC5 DT 12 Intermediate connector S-1
OPL DT 2 System operating lamp C-8
40-82 HD465-8, HD605-8

Number
of pins
OPM AMP070 6 Machine monitor control R-1
P1_G DT 3 Bkup speed sensor-A AK-7
P1_G_RES DT 2 Fuel supply pump pull up resistance 620 Ω AK-6
P1_PCV1 SUMITOMO 2 Supply pump PCV1-A AK-8
P1_PCV2 SUMITOMO 2 Supply pump PCV2-A AK-8
P23 DT 2 Heated wire mirror (if equipped) -
P2_G DT 3 Bkup speed sensor-B AK-7
P2_G_RES DT 2 Fuel supply pump pull up resistance 620 Ω AK-6
P2_PCV1 SUMITOMO 2 Supply pump PCV1-B AK-7
P2_PCV2 SUMITOMO 2 Supply pump PCV2-B AK-8
PAMB FRAMATOME 3 Atmospheric temperature sensor AL-5
PBS SWP 6 Parking brake manual switch N-3
PCCV FRAMATOME 3 Crankcase pressure sensor AL-4
PDL BENDIX 5 Download connector C-2
PFUEL AMP 3 Common rail pressure sensor AO-9
PIM FRAMATOME 3 Boost pressure sensor AL-4
PL01 DT 2 Headlamp (L.H.)(Hi) E-1
PL02 DT 2 Headlamp (L.H.)(Lo) F-1
PL03 DT 3 Combination lamp (L.H.) E-1
PL06 AMP 2 Fog lamp (L.H.) (if equipped) F-1
PL07 Terminal 1 Ground E-1
PLMm BENDIX 5 Middle connector V-8
PLMo BENDIX 5 Middle connector W-8
PLS SWP 6 Power window switch (L.H.) Q-9
PM3 DT 3 Incline angle sensor T-9
PMLA DT 8 Middle connector I-9
PMRA DT 8 Middle connector E-9
POIL FRAMATOME 3 Engine oil pressure sensor AM-5
PPSR EJ2 3 Parking brake pressure sensor J-3
PR01 DT 2 Headlamp (R.H.)(Hi) B-5
PR02 DT 2 Headlamp (R.H.)(Lo) B-5
PR03 DT 3 Combination lamp (R.H.) B-5
PR04 DT 2 Warning lamp (turns) (if equipped) B-6
PR06 AMP 2 Fog lamp (R.H.) (if equipped) B-4
PR07 Terminal 1 Ground B-4
PRS SWP 6 Power window switch (R.H.) Q-8
PSR DT 2 Parking brake solenoid K-1
PWL M 2 Power window motor (L.H.) W-3
HD465-8, HD605-8 40-83

Number
of pins
PWM2 SWP 6 Engine mode switch O-3
PWR HD30 23 Middle connector I-2
PWR M 2 Power window motor (R.H.) Q-8
R,PS DT 2 Solenoid (R) AH-9
R,SW DT 2 Fill switch (R) AH-9
R1 Terminal 1 Start switch connector R1 O-1
R01 Relay 5 Engine start relay N-9
R02 Relay 5 Start motor cutoff relay M-9
R03 Relay 5 Brake lamp operation relay (L.H./R.H.) M-9
R04 Relay 6 Backup lamp / buzzer relay M-8
R05 Relay 5 Brake lamp operation relay (center) M-7
R06 Relay 5 Through relay N-9
R07 Relay 5 Headlamp (Hi) relay N-9
R08 Relay 5 Headlamp (Lo) relay M-8
R09 Relay 5 Horn relay M-8
R10 Relay 6 Hazard relay 1 M-7
R11 Relay 5 Hazard relay 2 O-9
R12 Relay 6 Fog lamp relay (if equipped) P-9
R13 Relay 6 Work lamp relay P-8
R14 Relay 5 Revolving lamp relay (if equipped) P-8
R16 Relay 5 Door solenoid relay N-9
R17 Relay 5 Automatic secondary steering relay O-9
R18 Relay 5 Transmission controller self-holding relay P-7
R19 Relay 5 Automatic pre-heating relay N-6
R20 Relay 5 Payload meter green indicator lamp relay O-9
R21 Relay 5 Payload meter orange indicator lamp relay O-9
R22 Relay 5 Payload meter red indicator lamp relay O-9
R24 Relay 5 Ladder lamp relay (if equipped) P-7
R26 Relay 5 Parking brake safety relay P-8
R27 Relay 5 Parking interlock relay O-6
R30 YAZAKI 11 Power window relay U-9
R35 Relay 5 Engine start self-holding relay P-7
RAD YAZAKI 9 Radio P-3
RADS DT 4 Middle connector B-3
RE1 D08027 2 Resistor Q-1
RE5 DT 3 Terminating resistor X-3
40-84 HD465-8, HD605-8

Number
of pins
RE6 M 2 Resistor F-1
RE7 M 2 Resistor B-5
RE9 M 2 Resistor (if equipped) B-3
RE9 M 2 Resistor (if equipped) BJ-3
REVR DT 2 Retarder valve L-1
RL D08027 2 Cabin lamp Z-8
RL2 D08027 2 Cabin lamp 2 AC-9
RLA DT 12 Middle connector L-3
RLB DT 12 Middle connector L-3
RLY Terminal 1 Intake air heater relay B-2
RM1 SWP 6 Brightness adjustment switch N-3
RMN1 AMP070 12 Rearview monitor M-3
RMN2 AMP070 8 Rearview monitor M-2
RP DT 8 Middle connector B-4
RPE DT 2 Radiator fan pump EPC valve J-1
RRS DT 2 Radiator fan reverse solenoid B-4
RSS DT 2 Radiator fan speed sensor B-4
RTL DT 6 Retarder control lever potentiometer P-2
RTR DT 2 Retarder oil temperature sensor (R.H.) I-9
RTSR EJ2 3 Retarder brake pressure sensor L-1
RVC1 DT 4 Rearview camera L-9
S01 DT 3 Service brake pressure switch I-2
S02 EJ2 3 Secondary brake pressure sensor H-9
S03 DT 2 Front brake cut valve I-9
S04 DT 2 Automatic suspension solenoid 1 (if equipped) L-6
S05 DT 2 Automatic suspension solenoid 2 (if equipped) L-6
SAC DT 4 KTCS acceleration sensor (if equipped) T-1
SBS DT 2 Seat belt switch U-1
SCS DT 2 PNC solenoid K-1
SDC DT 2 Middle connector C-8
SDE SWP 6 Work lamp switch R-1
SEGR DT 4 EGR valve lift sensor AM-5
SES DT 2 Middle connector D-1
SES DT 2 Emergency engine stop switch (if equipped) BM-1
SF1 DT 12 Gear shift lever M-3
SF2 DT 2 Gear shift lever M-3
SHOF DT 2 Hydraulic oil filter switch (if equipped) -
SIG HD30 31 Middle connector H-2
HD465-8, HD605-8 40-85

Number
of pins
SLL1 DT 2 Middle connector K-1
SLL2 DT 2 Work lamp (L.H) K-3
SLR1 DT 2 Middle connector E-9
SLR2 DT 2 Work lamp (R.H) D-8
SPA DT 12 Middle connector D-1
SPARE SWP 6 Middle connector T-9
SPCS DT 2 Steering pump lockout solenoid (if equipped) I-2
SPL M 2 Speaker (L.H.) AD-8
SPR M 2 Speaker (R.H) AA-9
SR3 X 3 Steering speed sensor (if equipped) P-2
ST1 Terminal 1 Secondary steering switch N-3
STP-C DT 3 Brake lamp, Rear lamp (middle) L-9
STP-L DT 3 Brake lamp, Rear lamp (L.H.) L-8
STP-R DT 3 Brake lamp, Rear lamp (R.H.) J-8
STR DT 2 Steering oil temperature sensor L-2
STSW DT 6 Middle connector M-1
SUFL DT 3 Suspension cylinder pressure sensor (left front) K-4
SUFR DT 3 Suspension cylinder pressure sensor (right front) B-7
SURL DT 3 Suspension cylinder pressure sensor (left rear) L-8
SURR DT 3 Suspension cylinder pressure sensor (right rear) K-9
SVGT DT 3 VGT position sensor AO-6
T/C,P DT 3 Torque converter middle pressure sensor AE-1
T/C,T DT 2 Torque converter output oil temperature sensor AF-1
T/M,T DT 2 Transmission lubricant oil temperature sensor AJ-2
T1 Terminal 1 Ground AJ-5
T10 - 3 Middle connector M-7
T10A DT 3 Incline angle sensor N-6
TCS1 DT 3 Steering angle sensor F-1
TCS2 DT 2 KTCS shut off solenoid (if equipped) K-7
TCS3 DT 2 KTCS valve (R.H.) (if equipped) J-8
TCS4 DT 2 KTCS valve (L.H.) (if equipped) I-8
TCS5 EJ2 3 KTCS pressure sensor (R.H.) (if equipped) J-8
TCS6 EJ2 3 KTCS pressure sensor (L.H.) (if equipped) J-8
40-86 HD465-8, HD605-8

Number
of pins
TCSA1 DT 12 Middle connector L-3
TCSA2 DT 12 Middle connector K-7
TCSB1 DT 12 Middle connector L-3
TCSB2 DT 12 Middle connector K-8
TIM PACKARD 2 Boost temperature sensor AM-5
TM2 HD30 23 Middle connector AJ-4
TM3 HD30 31 Middle connector AJ-4
TMF1 DT 2 Transmission oil filter switch 1 L-4
TMF2 DT 2 Transmission oil filter switch 2 K-4
TOIL PACKARD 2 Engine oil temperature sensor AP-2
TWTR PACKARD 2 Coolant temperature sensor AP-3
UNT DT 2 Unit switching connector W-9
VATS DT 3 Ambient temperature sensor D-1
VGT_REV DT 2 VGT speed sensor AO-8
VGT_SOL DT 2 VGT Solenoid AO-6
VH1 DT 12 Middle connector X-6
Oil pressure sensor for primary flow rate selector
VOL,P EJ2 3 AE-4
valve
VOL,PS DT 2 Primary flow rate selector valve AE-3
WFM M 6 Wiper motor Q-2
WFR D08027 6 Wiper relay R-1
WIN-L DT 3 Turn signal lamp (L.H.) L-8
WIN-R DT 3 Turn signal lamp (R.H.) J-9
WLM RJ45 8 Wireless LAN modem B-5
WPCS DT 2 Steering/hoist pump lockout solenoid (if equipped) I-1
WPP DT 3 Steering/hoist pump oil pressure sensor (if equipped) H-1
WPS DT 12 Wiper switch Q-2
WSFL DT 2 Wheel speed sensor (front left) (if equipped) AS-2
WSFR DT 2 Wheel speed sensor (front right) (if equipped) AR-5
WSRL DT 2 Wheel speed sensor (rear left) (if equipped) L-7
WSRR DT 2 Wheel speed sensor (rear right) (if equipped) J-8
HD465-8, HD605-8 40-87

1/13
40-88 HD465-8, HD605-8

2/13
HD465-8, HD605-8 40-89

3/13
40-90 HD465-8, HD605-8

4/13
HD465-8, HD605-8 40-91

5/13
40-92 HD465-8, HD605-8

6/13
HD465-8, HD605-8 40-93

7/13
40-94 HD465-8, HD605-8

8/13 (Machine with ABS system)
HD465-8, HD605-8 40-95

40-96 HD465-8, HD605-8

HD465-8, HD605-8 40-97

11/13 (Machine with with emergency engine stop switch)
40-98 HD465-8, HD605-8

HD465-8, HD605-8 40-99

40-100 HD465-8, HD605-8

40 TROUBLESHOOTING CONNECTOR CONTACT IDENTIFICATION
CONNECTOR CONTACT IDENTIFICATION

(Rev.2014.11)
The male or female is for pin, and the convex or concave is for fitting (case).
HD465-8, HD605-8 40-101

CONNECTOR CONTACT IDENTIFICATION 40 TROUBLESHOOTING
40-102 HD465-8, HD605-8

HD465-8, HD605-8 40-103

40-104 HD465-8, HD605-8

HD465-8, HD605-8 40-105

40-106 HD465-8, HD605-8

HD465-8, HD605-8 40-107

40-108 HD465-8, HD605-8

HD465-8, HD605-8 40-109

40-110 HD465-8, HD605-8

HD465-8, HD605-8 40-111

40-112 HD465-8, HD605-8

HD465-8, HD605-8 40-113

40-114 HD465-8, HD605-8

HD465-8, HD605-8 40-115

40-116 HD465-8, HD605-8

HD465-8, HD605-8 40-117

40-118 HD465-8, HD605-8

HD465-8, HD605-8 40-119

40-120 HD465-8, HD605-8

HD465-8, HD605-8 40-121

40-122 HD465-8, HD605-8

HD465-8, HD605-8 40-123

40-124 HD465-8, HD605-8

HD465-8, HD605-8 40-125

40-126 HD465-8, HD605-8

HD465-8, HD605-8 40-127

40-128 HD465-8, HD605-8

HD465-8, HD605-8 40-129

40-130 HD465-8, HD605-8

HD465-8, HD605-8 40-131

40-132 HD465-8, HD605-8

HD465-8, HD605-8 40-133

40-134 HD465-8, HD605-8

HD465-8, HD605-8 40-135

40-136 HD465-8, HD605-8

HD465-8, HD605-8 40-137

40-138 HD465-8, HD605-8

*: No. 1 and 7 pin in the male pin side, (12-pin connector) do not exist.
HD465-8, HD605-8 40-139

40-140 HD465-8, HD605-8

40 TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH ADAPTER TABLE
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE

(Rev.2014.11)
The vertical part number record is for T-boxes and T-adapters. The horizontal part number record is for the harness test as-
semblies.
T-adapter kit
Number of pins
Non-kit part
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Part No. Part name ID marking
799-601-2600 T-box (for ECONO) 21 ● ● ● ● ●

799-601-3100 T-box (for MS) 37 ●
799-601-3200 T-box (for MS) 37 ●
799-601-3380 Plate for MS (14 pins) ●
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P ●
799-601-3470 Case ●
799-601-2710 Adapter for MIC 5 MIC-5P ● ● ●
799-601-2720 Adapter for MIC 13 MIC-13P ● ● ●
799-601-2730 Adapter for MIC 17 MIC-17P ● ● ● ● ● ●
799-601-2740 Adapter for MIC 21 MIC-21P ● ● ● ● ● ●
799-601-2950 Adapter for MIC 9 MIC-9P ● ● ● ●
799-601-2750 Adapter for ECONO 2 ECONO 2P ● ●
799-601-2810 Adapter for DLI 8 DLI-8P ● ●
Extension cable
799-601-2840 12 ECONO 12P ● ● ●
(ECONO type)
799-601-2850 Case ●
T-box (for DRC60,
799-601-4350 60 ●
ECONO)
HD465-8, HD605-8 40-141

T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 40 TROUBLESHOOTING
T-adapter kit
Number of pins
Non-kit part
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
799-601-4360 Case ●
Adapter for X
799-601-7010 1 ● ●
(T-adapter)
799-601-7020 Adapter for X 2 X2P ● ● ● ●
799-601-7030 Adapter for X 3 X3P ● ● ● ●
799-601-7040 Adapter for X 4 X4P ● ● ● ●
799-601-7050 Adapter for SWP 6 SW6P ● ● ●
799-601-7060 Adapter for SWP 8 SW8P ● ● ●
799-601-7310 Adapter for SWP 12 SW12P ●
799-601-7070 Adapter for SWP 14 SW14P ● ●
799-601-7320 Adapter for SWP 16 SW16P ●
Adapter for M
799-601-7080 1 ● ●
(T-adapter)
799-601-7090 Adapter for M 2 M2P ● ● ● ●
799-601-7110 Adapter for M 3 M3P ● ● ● ●
799-601-7120 Adapter for M 4 M4P ● ● ● ●
799-601-7130 Adapter for M 6 M6P ● ● ● ●
799-601-7340 Adapter for M 8 M8P ●
799-601-7140 Adapter for S 8 S8P ● ● ● ●
799-601-7150 Adapter for S (white) 10 S10P ● ● ● ●
799-601-7160 Adapter for S (blue) 12 S12P ● ● ●
799-601-7170 Adapter for S (blue) 16 S16P ● ● ● ●
799-601-7330 Adapter for S (white) 16 S16PW ●
799-601-7350 Adapter for S (white) 12 S12PW ●
799-601-7180 Adapter for AMP040 8 A8P ●
799-601-7190 Adapter for AMP040 12 A12P ● ●
799-601-7210 Adapter for AMP040 16 A16P ● ● ● ●
799-601-7220 Adapter for AMP040 20 A20P ● ● ● ●
799-601-7230 Short socket adapter for X 2 ● ● ● ●
799-601-7240 Case ● ●
799-601-7270 Case ●
799-601-7510 Adapter for 070 10 07-10 ●
799-601-7520 Adapter for 070 12 07-12 ●
799-601-7530 Adapter for 070 14 07-14 ●
799-601-7540 Adapter for 070 18 07-18 ●
799-601-7550 Adapter for 070 20 07-20 ●
799-601-7360 Adapter for relay 5 REL-5P ●
40-142 HD465-8, HD605-8

T-adapter kit
Number of pins
Non-kit part
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
799-601-7370 Adapter for relay 6 REL-6P ●

799-601-7380 Adapter for JFC 2 ●
799-601-9010 Adapter for DTM 2 DTM2 ● ●
799-601-9020 Adapter for DT 2 DT2 ● ● ● ●
799-601-9030 Adapter for DT 3 DT3 ● ●
799-601-9040 Adapter for DT 4 DT4 ● ● ● ●
799-601-9050 Adapter for DT 6 DT6 ● ●
799-601-9060 Adapter for DT (gray) 8 DT8GR ● ●
799-601-9070 Adapter for DT (black) 8 DT8B ● ●
799-601-9080 Adapter for DT (green) 8 DT8G ● ●
799-601-9090 Adapter for DT (brown) 8 DT8BR ● ●
799-601-9110 Adapter for DT (gray) 12 DT12GR ● ●
799-601-9120 Adapter for DT (black) 12 DT12B ● ●
799-601-9130 Adapter for DT (green) 12 DT12G ● ●
799-601-9140 Adapter for DT (brown) 12 DT12BR ● ●
799-601-9210 Adapter for HD30-18 8 D18-8 ● ●
799-601-9220 Adapter for HD30-18 14 D18-14 ● ●
799-601-9230 Adapter for HD30-18 20 D18-20 ● ●
799-601-9240 Adapter for HD30-18 21 D18-21 ● ●
799-601-9250 Adapter for HD30-24 9 D24-9 ● ●
799-601-9260 Adapter for HD30-24 16 D24-16 ● ●
799-601-9270 Adapter for HD30-24 21 D24-21 ● ●
799-601-9280 Adapter for HD30-24 23 D24-23 ● ●
799-601-9290 Adapter for HD30-24 31 D24-31 ● ●
799-601-9310 Plate for HD30 (24 pins) ● ● ●
799-601-9320 T-box (for ECONO) 24 ● ● ●
799-601-9330 Case ●
799-601-9340 Case ●
799-601-9350 Adapter for DRC 40 DRC-40 ●
799-601-9360 Adapter for DRC 24 DRC-24 ●
Socket for engine
799-601-9410* 2 G ●
(CRI-T2)
Adapter for engine
(CRI-T2)
799-601-9420 Adapter PFUEL for 3 A3 ● ●
engine (CRI-T3)
Oil pressure sensor
HD465-8, HD605-8 40-143

T-adapter kit
Number of pins
Non-kit part
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Socket for engine

(CRI-T2)
799-601-9430* 2 P ● ●
Socket PCV for engine
(CRI-T3)
Socket for engine
799-601-9440* 3 1, 2, 3 ●
(CRI-T2)
Socket for engine
795-799-5520* 2 S ●
(HPI-T2)
Socket for engine
(HPI-T2)
795-799-5530* Socket for engine 2 C ● ●
(CRI-T3)
Temperature sensor
Socket for engine
(HPI-T2)
795-799-5540* 2 A ● ●
Socket TIM for engine
(CRI-T3)
Cable for engine
795-799-5460 3 ●
(HPI-T2)
Cable for engine
795-799-5470 3 ●
(HPI-T2)
Cable for engine
795-799-5480 3 ●
(HPI-T2)
Adapter PIM for engine
799-601-4110 4 ITT3N ● ●
(140-T3)
Adapter NE, CAM for
799-601-4130 3 FCIN ● ●
engine (CRI-T3)
Adapter for engine
799-601-4140 (CRI-T3) 3 FCIG ● ●
Ambient pressure
Adapter POIL for engine
799-601-4150 3 FCIB ● ●
(CRI-T3)
Adapter for engine
799-601-4160 (CRI-T3) 2 4160 ● ●
Oil pressure switch
Adapter PEVA for
799-601-4180 3 4180 ● ●
engine (CRI-T3)
Socket for engine
799-601-4190* (CRI-T3) 3 1, 2, 3L ● ●
Common rail pressure
Socket for engine
(CRI-T3)
799-601-4230* 4 1, 2, 3, 4C ● ●
Intake pressure/temper-
ature
Socket PAMB for engine
799-601-4240* 3 1, 2, 3A ● ●
(CRI-T3)
40-144 HD465-8, HD605-8

T-adapter kit
Number of pins
Non-kit part
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Socket PIM for engine

799-601-4250* 3 1, 2, 3B ● ●
(CRI-T3)
Socket G for engine
799-601-4330* 3 1, 2, 3G ● ●
(CRI-T3)
Socket for engine
799-601-4340* (CRI-T3) 2 2, PA ● ●
Pump actuator
Socket for engine
(CRI-T3) (95)
799-601-4380* 4 1, 2, 3, 4T ●
Intake pressure/temper-
ature
Adapter for controller
799-601-4260 4 DTP4 ● ●
(ENG)
799-601-4211 50 DRC50 ●
(ENG)
799-601-4220 60 DRC60 ●
(ENG)
Socket for controller
799-601-4390* 60 ●
(95ENG)
Case for controller
799-601-4280* 121 ●
(PUMP)
799-601-9720 16 HST16A ●
(HST)
799-601-9710 16 HST16B ●
(HST)
799-601-9730 26 HST26A ●
(HST)
Multi-adapter for DT 2 to 2,
799-601-9890 ●
4, DTM 2 pins 3, 4
T-adapter for ICT con-
799-902-9600 26 ●
trol box
799-902-9700 T-box 26 ●
*: These are not T-adapters but sockets.
T-adapter kit
Number of pins
Non-kit part
799-A65-4600
799-902-9300
799-601-4620 Adapter for controller (ENG-T4) 4 799-601-4620 ●
HD465-8, HD605-8 40-145

T-adapter kit
Number of pins
Non-kit part
799-A65-4600
799-902-9300
799-902-9310 Adapter for control box 19 799-902-9310 ●
799-902-9320 Adapter for IMU 10 799-902-9320 ●
799-902-9330 Adapter for MS cylinder 6 799-902-9330 ●
The KDPF difference of pressure sensor

799T-601-4611 4 799T-601-4611 ●
short socket adapter
KDPF output pressure sensor short socket

799T-601-4670 4 799T-601-4670 ●
adapter
799T-601-4680 KDPF dummy temperature sensor 4 799T-601-4680 ●
40-146 HD465-8, HD605-8

40 TROUBLESHOOTING FUSE LOCATION TABLE
FUSE LOCATION TABLE

Connection table of the circuit breaker and fuse case
REMARK
q This connection table shows the circuit breaker, fuse case and the
devices which receive the power from the fuse case. An alternate
power supply is the power supplied only while the start switch is in
the ON position. A continuous power supply is the power supplied
whether or not the start switch is at the OFF or ON position.
q When you troubleshoot in relation to the electrical system and the
supplied power is normal, examine the breaker and fuse.
q Location and connection table for the circuit breaker (60A, 60A, 105A, 105A) in the battery case and slow-blow fuse.
Type of power Breaker No. Capacity of

Destination of power (pin No.)
supply (Terminal No.) breaker
1
60 A Fuse case BT3 (17), (19)
(66, 67)
Continuous
power supply All of fuse case BT2
2
60 A
(68, 69)
Fuse case BT4 (21) to (29), BT5 (19)
3
Alternate power 105 A Fuse case BT1 (1) to (11), (19) to (29)
(62, 63)
supply
(Battery relay Fuse case BT3 (1) to (15)
4
output) 105 A
(64, 65)
Fuse case BT4 (3) to (19), BT5 (1) to (11)
Type of power Breaker No.

Fuse capacity Destination of power
supply (Terminal No.)
Alternate power
supply 5
120 A Intake air heater power supply
(Battery relay (81, 83)
output)
Continuous 6
15 A Secondary steering power supply
power supply (EMPR)
HD465-8, HD605-8 40-147

FUSE LOCATION TABLE 40 TROUBLESHOOTING
q Locations of fuse cases BT1 to BT5 and fuse No.
REMARK
Circled numbers correspond to connector numbers shown in the circuit diagrams of the related sections. You can troubleshoot
by failure code.
40-148 HD465-8, HD605-8

q Connection table of fuse case (BT1)
Type of power Breaker No. BT1

supply (Ampere) Fuse No.
1 10 A Primary lamp, clearance lamp
2 15 A Headlamp (Hi)
3 15 A Headlamp (Lo)
4 10 A Brake lamp
5 15 A Backup lamp, alarm buzzer
6 30 A Heated wire mirror power supply (if equipped)
7 10 A Heated wire mirror (R.H. top) (if equipped)

Alternate power
supply 3
8 10 A Heated wire mirror (L.H.) (if equipped)
(Battery relay out- (105 A)
put) 9 10 A Heated wire mirror (R.H. bottom) (if equipped)
10 15 A Automatic grease (if equipped)
11 20 A DC converter
12 20 A Air suspension seat
13 20 A Power window (R.H.)
14 20 A Power window (L.H.)
15 15 A Fog lamp (if equipped)
HD465-8, HD605-8 40-149

q Connection table of the fuse case (BT2)

Engine section lamp (if equipped) (continuous

1 15 A
power supply)
2 15 A Terminal B (continuous power supply)
3 5A Air conditioner (continuous power supply)
Retarder and hoist controller (continuous power

4 5A
supply)
Transmission controller (continuous power sup-

5 15 A
ply)
6 10 A Monitor panel (continuous power supply)
7 5A Rearview monitor (continuous power supply)

Continuous 2
power supply (60 A)
8 30 A Pump timer switch (continuous power supply)
9 10 A KOMTRAX (continuous power supply)
10 5A ID Key (if equipped) (continuous power supply)
11 10 A KOMTRAX Plus
12 10 A Download (continuous power supply)
13 5A ABS controller (if equipped)
Automatic lubricant (if equipped) (continuous

14 10 A
power supply)
15 20 A Spare (continuous power supply)

1 20 A Air conditioner (blower motor)
2 10 A Air conditioner (compressor clutch)
3 10 A Radio
Alternate power
4 20 A Front windshield wiper
supply 4
5 10 A Cabin lamp 2, door solenoid
put)
6 10 A Turn signal lamp
7 15 A Side lamp (if equipped)
8 15 A Warning lamp (turns) (if equipped)
9 30 A Engine controller (continuous power supply)

Continuous 1
power supply (60 A)
10 30 A Engine controller (continuous power supply)
40-150 HD465-8, HD605-8


Continuous 6
11 10 A Secondary steering (continuous power supply)
power supply (15 A)
12 5A Controller (ACC signal)
Alternate power 13 5A Air conditioner (ACC signal)

2
supply (start
(60 A)
switch BR) 14 10 A Download (ACC signal)
15 - -

Alternate power
2
supply (start 1 5A Parking brake
(60 A)
switch BR)
2 15 A Retarder and hoist controller
3 5A Gear shift lever, starting motor cut-off relay
4 5A Switch panel
Alternate power
5 - -
supply 4
6 10 A Automatic secondary steering
put)
7 15 A ABS controller (if equipped)
8 10 A PLM external display lamp
9 10 A Preheater relay
10 20 A Spare
11 15 A Step light (if equipped) (continuous power supply)
12 5A Radio (continuous power supply)

Continuous 2
power supply (60 A) 13 10 A Hazard lamp (continuous power supply)
Cabin lamp, system operation lamp (continuous

14 10 A
power supply)
15 15 A Horn (continuous power supply)
HD465-8, HD605-8 40-151

q Connection table of fuse box (BT5)

1 5A Smart sensor 1
2 5A Smart sensor 2
Alternate power
3 - -
supply 4
4 10 A External delivery
put)
5 30 A Glass heater (if equipped)
6 15 A Added heater (if equipped)
7 - -
- - 8 - -
9 - -
Continuous 4
10 10 A External delivery (continuous power supply)
power supply (105 A)
11 - -
12 - -
- - 13 - -
14 - -
15 - -
40-152 HD465-8, HD605-8

40 TROUBLESHOOTING PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF

and KDOC)
k Since KDPF and KDOC are hot, 500 °C or higher, take care not to get a burn injury.
Related information
Soot accumulation quantity of KCSF in KDPF is classified in 8 levels. From "Service menu" of the machine monitor, display
"Diagnostic Tests" screen, and present level of accumulated soot are examined on "In operation Regeneration for the Service"
screen.
These failure codes are shown corresponding to the soot accumulation level.
q If the soot accumulation level is 4 or 5, the failure code [CA2639] or [CB2639] is shown.
q If the soot accumulation level is 6 or 7, the failure code [CA1921] or [CB1921] is shown.
q If the soot accumulation level is 8, the failure code [CA1922] or [CB1922] is shown.
q If the soot accumulation level is 8, it is necessary to examine, clean or replace because KDPF is completely clogged
with soot.
q Manual stationary regeneration is performed to a (maximum) soot accumulation level 7, and soot in KCSF is then
burned and removed.
q If the soot accumulation level is 4 to 7, perform the manual stationary regeneration.
Manual stationary regeneration is performed from In Operation Regeneration for Service (see below) or from operator
mode.
Method of manual stationary regeneration from "Active Regeneration for Service".
q When the soot accumulation level is 3 or less, manual stationary regeneration is performed only from "Active Regeneration
for Service" refer the below procedure.
2. Secure the safety of the machine.
3. From "Service menu" of the machine monitor, display "Diagnostic Tests" screen, open "Active Regeneration for Service",
and then perform "Manual Stationary Regeneration".
q Time required for manual stationary regeneration varies with the quantity of soot accumulation in KCSF. Rough guide is
described below.
Soot accumulation level 4: Approximately 40 minutes to 1 hour
Soot accumulation level 5: Approximately 1 hour to 2 hours
q How to set KDPF (KCSF) clean.
From "Service menu" of the machine monitor, display "Diagnostic Tests" screen, open "KDPF Memory Reset", and per-
form "KDPF Cleaning" or "KDPF Cleaning_2" (again set KDPF to clean).
q How to set KDPF (KCSF) replace.
form "KDPF Change" or "KDPF Change_2" (again set KDPF change).
q If KCSF in KDPF is replaced, set the two again "KDPF Cleaning" or "KDPF Cleaning_2" and "KDPF Change" or "KDPF
Change_2". Then make sure to perform "Manual Stationary Regeneration" from "Active Regeneration for Service" to re-
move water from KCSF.
q How to set after KDOC change
form "KDOC Change" or "KDOC Change_2" (Reset KDOC change).
q If KDOC in KDPF is replaced, perform set again of "KDOC Change" or "KDOC Change_2" but it is not necessary to perform
manual stationary regeneration.
In the case of KCSF, clean or change

q At 4500 h period Periodical clean
1. If the soot accumulation level is shown, perform "Active Regeneration for Service" until it becomes zero.
2. Stop the engine, wait for the piping around the engine to be cool, and then remove the KDPF. Also, remove KCSF.
HD465-8, HD605-8 40-153

PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 40 TROUBLESHOOTING
NOTICE
Remove the 2 pieces of KDPF at the same time.
3. Clean the KCSF at the specified repair service. (If you use removed KCSF again after it is cleaned)
4. Install cleaned up KCSF to the machine. (If you use removed KCSF again after it is cleaned)
5. Install new KCSF to the machine. (If you change to a new KCSF)
6. Turn the start switch to ON. From "Service Menu" of the machine monitor, display "Diagnostic Tests" screen, open "KDPF
Memory Reset", and set again the "KDPF Cleaning" and "KDPF Cleaning_2".
7. On "KDPF memory Reset" screen, set again the "KDPF Change" and "KDPF Change_2".
After you set again the "KDPF Change" and "KDPF Change_2", the changes in the brackets are reflected. (Soot Correction
by Ash Influence is changed to 0 g/l.)
8. Start the engine, and run it at low idle to warm up.
9. Perform "Active Regeneration for Service".
q When, something is broken or any damage is found in check.
1. Stop the engine, wait for the piping around the engine cool, and then remove KDPF. Also, remove KCSF.
NOTICE
Remove the 2 pieces of KDPF at the same time.
2. Install alternative KCSF (new or used).
NOTICE
Replace the 2 pieces of KCSF at the same time. (Regardless of whether they are a couple of new and used.)
3. Turn the start switch to ON. From "Service Menu" of the machine monitor, display "Diagnostic Tests" screen, open "KDPF
Memory Reset", and again set the "KDPF Cleaning" and "KDPF Cleaning_2".
4. On "KDPF Memory Reset" screen, again set the "KDPF Change" and "KDPF Change_2".
5. Start the engine, and run it at low idle to warm up.
6. Perform "Active Regeneration for Service".
q When [CA1922]: "KDPF Soot Accumulation High Error 2" or [CB1922]: "KDPF Soot Accumulation High Error 2_2" is dis-
played
1. Stop the machine, and check that failure code [CA1922] or [CB1922] is displayed on the machine monitor.
2. Check the display record of [CA2639]: "Manual Stationary Regeneration Request", [CA1921]: "KDPF Soot Accumulation
High Error 1", [CA1922]: "KDPF Soot Accumulation High Error 2", [CB2639]: "Manual Stationary Regeneration Request_2",
[CB1921]: "KDPF Soot Accumulation High Error 1_2", and [CB1922]: "KDPF Soot Accumulation High Error 2_2" on the
machine monitor.
3. Calculate the time between displays [CA2639]/[CB2639] and [CA1921]/[CB1921], and time between displays
[CA1921]/[CB1921] and [CA1922]/[CB1922].
q If the time between displays [CA2639]/[CB2639] and [CA1921]/[CB1921], and between [CA1921]/[CB1921] and
[CA1922]/[CB1922] is ≥ 0.1 h, perform item 4, replace KCSF.
REMARK
Since the soot accumulation exceeds the limit which the regeneration can perform, KCSF is replaced when you remove
KDPF.
q If either time between displays [CA2639]/[CB2639] and [CA1921]/[CB1921]or between [CA1921] and
[CA1922]/[CB1922] is < 0.1 h, proceed to item 5, perform "Active Regeneration for Service".
REMARK
Actually, soot is not sedimented (equivalent to 9 g/l), but accumulation condition of soot is uneven and it makes clog-
ging and causes increase of differential pressure. With this level of soot accumulation, even if active regeneration is
performed, abnormal combustion does not occur. Accordingly, do not replace KCSF, perform Active Regeneration for
Service to reduce soot, and continue to use KCSF.
4. If KCSF changes
1) Stop the engine, wait for the piping around the engine to cool, and then remove KCSF.
40-154 HD465-8, HD605-8

40 TROUBLESHOOTING PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)
NOTICE
q Remove the 2 pieces of KDPF at the same time.
q Replace the 2 pieces of KCSF at the same time. (Regardless of whether they are a couple of new and used)
2) Install alternative KCSF (new or used).
3) Turn the start switch to ON. From "Service Menu" of the machine monitor, display "Diagnostic Tests" screen, and again
set the "KDPF Cleaning" or "KDPF Cleaning_2" from the "KDPF Memory Reset" screen.
After you again set the "KDPF Cleaning" and "KDPF Cleaning_2", the changes in the brackets are reflected. (Soot
accumulation: 9 g/l → 8.1 g/l, action level: L04 → L03, failure code: [CA1922] → [CA1921] or [CB1922] → [CB1921])
4) From "Service Menu" of the machine monitor, display "Diagnostic Tests" screen, and again set the "KDPF Change" and
"KDPF Change_2" from the "KDPF Memory Reset" screen.
After you again set the "KDPF Change", the changes in the brackets are reflected. (Soot Correction by Ash Influence
is changed to 0 g/l.)
5) Start the engine, and run it at low idle to warm up.
6) Perform "Active Regeneration for Service". ("Active Regeneration for Service" may continue for approximately 2 hours.)
7) Make sure that failure codes [CA1922], [CA1921], [CA2639], [CB1921], [CB1922], and [CB2639] are not shown after
"Active Regeneration for Service" is complete.
5. When you perform "Active Regeneration for Service"
NOTICE
When you perform the "Active Regeneration for Service" (It is not necessary to remove KDPF), do not again set
"KDPF Change" and "KDPF Change_2".
If KDPF Change and KDPF Change_2 are reset, Soot Correction by Ash Influence calculated in engine controller
becomes 0 g/l, and it differs from actual ash accumulation value in KDPF.
When resetting KDPF Change and KDPF Change_2 by any chance, and Soot Correction by Ash Influence becomes
0 g/l, see TEST AND ADJUST, "SET AND OPERATE OF MACHINE MONITOR", "SERVICE MODE", "PROCEDURE
TO OPERATE ASH IN SOOT ACCUMULATION CORRECTION TEST MENU".
Make sure that there is no problem with the sensor system. Troubleshoot and then perform it.
1) Start the engine and run it at low idle to warm up the engine. From "Service Menu" of the machine monitor, display
"Diagnostic Tests" screen, and again set the "KDPF Cleaning" and "KDPF Cleaning_2" from the "KDPF Memory Reset"
screen.
After you again set the "KDPF Cleaning", the changes in the brackets are reflected. (Soot accumulation: 9 g/l → 8.1
g/l, action level: L04 → L03, failure code: [CA1922] → [CA1921] or [CB1922] → [CB1921])
2) Perform "Active Regeneration for Service". ("Active Regeneration for Service" may continue for approximately 2 hours.)
3) Make sure that failure codes [CA1922], [CA1921], [CA2639], [CB1921], [CB1922], and [CB2639] are not shown after
"Active Regeneration for Service" is complete.
6. When [CA5383] "Ash Accumulation High Error" or [CB5383] "Ash Accumulation High Error_2" is shown
Examine results of failure code [CA5383] or [CB5383]. If the expected cause is "Ash Accumulation High", perform the same
procedure ("At the 4500 H period periodical cleaning" in "In case of KCSF cleaning or change") described in precautions
of this chapter.
If you clean or change KDOC

q When broken or damaged parts are found in check
1. When damage or crack is found in KDOC, change KDOC.
NOTICE
KDOC, which has 2 pieces, is replaced together.
2. From the "Service Menu" of the machine monitor, display "Diagnostic Tests" screen, and again set the "KDOC Change"
and "KDOC Change_2" from the "KDPF Memory Reset" screen.
q When Defective regeneration [CA1691] or [CB1691] is shown
1. Stop the machine, and make sure that failure code [CA1691] or [CB1691] is shown on the machine monitor.
([CA2637] or [CB2637] may show at the same time.)
HD465-8, HD605-8 40-155

PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 40 TROUBLESHOOTING
2. Examine the exhaust gas color.

3. Stop the engine, wait for the piping around the engine to be cooled down, and remove KDOC, and then check it for damage
or crack.
4. When a crack or damage is found in KDOC
1) Replace KDOC.
2) From the "Service Menu" of the machine monitor, show the "Diagnostic Tests" screen, and again set the "KDOC
Change" and "KDOC Change_2" from the "KDPF Memory Reset" screen.
5. When no cracks or damage is found in KDOC
1) Clean KDOC and install it again.
2) From the "Service Menu" of the machine monitor, show the "Diagnostic Tests" screen, and again set the "KDOC
Change" and "KDOC Change_2" from the "KDPF Memory Reset" screen.
3) Perform "Active Regeneration for Service" twice. (The fuel is injected during regeneration.)
REMARK
When you perform "Active Regeneration for Service" continuously, stop the engine once.
To again start the engine, wait until system operating lamp goes out after you turn the start switch to OFF. Then, turn
the start switch to ON.
4) If [CA2637]: "KDOC Face Plugging" or [CB2637]: "KDOC Face Plugging_2" is shown after you perform the "Active
Regeneration for Service", KDOC performance is decreased, replace KDOC.
40-156 HD465-8, HD605-8

40 TROUBLESHOOTING PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR
PREPARATION FOR TROUBLESHOOTING OF MACHINE

MONITOR
q Machine monitor has many units which independently transmit / receive data to / from the monitor controller through the
LIN (Local Interconnect Network) communication.
q Connectors in Table 1 are used on each unit related to the machine monitor.
q Create a harness check tool to troubleshoot the LCD unit of the machine monitor. See "PROCEDURES FOR CREATING
HARNESS CHECKER ON MACHINE MONITOR LCD UNIT" for procedure to create a harness check tool for the machine
monitor LCD unit.
Table 1. Details of connectors related to the machine monitor
Con- Num- Manu-

Model num- Connector
Unit name nector ber of fac- Tool Remarks
ber type, etc
name pins turer
MX40008U
LC unit DPC1 8 JAE -
-Q1
Machi
ne 070 Connec-
LED unit DPC2 6 175954-1 AMP T-adapter
monitor
tor
070 Connec-
Meter unit DPC3 8 175955-1 AMP T-adapter
tor
- MCM1 81 This is not

Same as the T-adapter.
TYCO-124 Box type
AMP pump con- Working pres-
1434 socket
- MCM2 40 troller of PC sure cannot be
measured.
Monitor control- See "PROCE-

ler DURES FOR
CREATING
MX40008N Harness HARNESS
- MCM3 8 JAE
Q1 checker CHECKER ON
MACHINE
MONITOR LCD
UNIT".
070 Connec-
- Switch panel OPM 6 175954-1 AMP T-adapter
tor
070 Connec-
- RMN1 12 175957-1 AMP T-adapter
tor
Rearview moni-
tor
070 Connec-
- RMN2 8 175955-1 AMP T-adapter
tor
HD465-8, HD605-8 40-157

PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 40 TROUBLESHOOTING
Circuit diagram related to the machine monitor
40-158 HD465-8, HD605-8

PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE
40 TROUBLESHOOTING MONITOR LCD UNIT
PROCEDURES FOR CREATING HARNESS CHECKER ON

MACHINE MONITOR LCD UNIT
1. Function
This procedure describes how to make a check harness for the machine monitor. It uses a mass made wiring harness be-
tween the machine monitor LCD unit and monitor controller.
q Data transmitted from the monitor controller is shown on the machine monitor LCD unit.
q An output voltage indication from the monitor controller using the check harness determines whether the monitor con-
troller is the cause of the failure.
q The monitor check harness is used to troubleshoot the machine monitor LCD unit. (See E-mode, "LCD UNIT ON MA-
CHINE MONITOR DISPLAYS NOTHING" to "LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY".)
2. General
Mass made wiring harness between the machine monitor LCD unit and the monitor controller: 7831-47-8710
q Before changes
HD465-8, HD605-8 40-159

MONITOR LCD UNIT 40 TROUBLESHOOTING
q After changes
1) Modify P parts.
2) Cut off the one side of connector (the side without seal). Install insulation for each line (not to cause short circuit), and
install check pins.
3) The check harness is now completed.
Fig. 1 Mass made wiring harness between the machine monitor LCD unit and the monitor controller: 7831-47-8710
40-160 HD465-8, HD605-8

REMARK
Pin number of the check pin corresponds to color of Q piece or depends on which pin on the opposite side it is connected to.
3. Prepare
q Items to prepare
No. Part name Model Manufacturer Q'ty
Japan Aviation Elec-

1 Wiring harness 7831-47-8710 1
tronics Industry, Ltd.
SATO PARTS
2 Check pin TJ-1-W *1 8
CO.,LTD.
Sumitomo Electric
3 Heat shrink tube φ5 mm (Length Min. 35 mm) SUMI-F2Z-5×0.25 *1 1
Industries, Ltd
Heat shrink tube φ3.5 mm (Length Min. 140 Sumitomo Electric

4 SUMI-F2Z-3.5×0.25 *1 1
mm) Industries, Ltd
One of each
5 Sticker with number (<1> to <8> is written) *2 - (Create your own)
(total 8)
6 Vinyl tape - - 1
7 Wire cutters - - 1
8 Wire stripper (for AWG 20 to 34) - - 1
9 Utility knife - - 1
10 Soldering iron - - 1
11 Solder - - 1
HD465-8, HD605-8 40-161

No. Part name Model Manufacturer Q'ty
12 Dryer *3 - - 1
*1 Use an equivalent product as the replacement.

*2 This is used for pin No. of harness to be easily identified. You can also put a mark on it.
*3 A heat tool is a possible replacement.
4. Work procedure
q Changes to pins No. 3 thru No. 8
1) Cut off the connector without insulation (without (07) of Fig.1) of wiring harness at its bottom with a wire cut tool.
2) Use an insulation removal tool. Remove 5 mm of the insulation from the wire of pins No. 3 thru No. 8 (which are cut off).
NOTICE
Be careful not to harm the other wires or cut them.
3) Prepare the φ3.5 mm (6 pieces) heat shrink tube cut to a length of 15 mm (A).
4) Put the wire through the heat shrink tube (A), and solder the check pin.
5) Put the heat shrink tube (A) (from Step 4 above) over the wire to where the check pin is not seen. Heat the heat shrink
tube (A) with a dryer.
6) Attach the label with the pin number of the wire to be identified.
REMARK
Pin number of the check pin corresponds to color of Q piece or depends on which pin on the opposite side it is con-
nected to.
40-162 HD465-8, HD605-8

7) Perform the same procedure on wire pins 4 thru 6 as done for wire No. 3 thru No. 8.
8) Unwind tape (B) wound onto the tube to an appropriate position.
q Changes to pins No. 1 and No. 2

1) Remove 35 mm of insulation from the protected wire.
NOTICE
Do not to harm or cut the other wires.
2) Remove the wire (with insulation) (C) and wrap it around the layer side.
3) Remove the aluminum foil and thin yellow paper (D), wrap around the layer side.
4) Remove 5 mm of the insulation from the wires of pins No. 1 and No. 2.
5) Prepare a length of 35 mm heat shrink tube (E), φ5 mm (1 piece).
6) Put the wire from pins No. 1 and No. 2 through heat shrink tube (E).
HD465-8, HD605-8 40-163

7) Prepare two lengths of 25 mm heat shrink tube (F), φ3.5 mm (2 pieces)

8) Put the wire from pins No. 1 and No. 2 through heat shrink tube (F).
9) Solder the check pin to the wires of pins No. 1 and No. 2.
10) Slide the heat shrink tube (F) of the wire to where it covers the check pin.
11) Attach the label with the pin number of the wire to be identified.
REMARK
Pin number of the check pin corresponds to color of Q piece or depends on which pin on the opposite side it is con-
nected to.
12) Slide heat shrink tube (E)(φ5 mm) to were it overlaps at pins No. 1 and No. 2 of heat shrink tube (F)(φ3.5 mm). Heat
the shrink tube (E) to compress and secure it.
13) Cut off tape (B), (removed from the conduit tube) at an appropriate position. Wrap vinyl tape around the wires of pins
No. 3 thru No. 8 to bind them.
14) Work to make the check harness is completed.
40-164 HD465-8, HD605-8

PREPARATION OF SHORT SOCKET ADAPTER (FOR FAILURE CODES
40 TROUBLESHOOTING [CA1883], [CB1883], [CA3135], AND [CB3135])
PREPARATION OF SHORT SOCKET ADAPTER (FOR FAILURE

CODES [CA1883], [CB1883], [CA3135], AND [CB3135])
NOTICE
The KDPF difference of pressure sensor and the KDPF output pressure sensor use the same connector.
Contained in set part No. 799-A65-4600.
Short socket adapter for the KDPF difference of pressure sensor used in failure code [CA1883] and [CB1883]
HD465-8, HD605-8 40-165

PREPARATION OF SHORT SOCKET ADAPTER (FOR FAILURE CODES
[CA1883], [CB1883], [CA3135], AND [CB3135]) 40 TROUBLESHOOTING
Short socket adapter for the KDPF output pressure sensor used in failure code [CA3135] and [CB3135]
40-166 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODES TABLE
FAILURE CODES TABLE

Applicable History cate-
Failure code Failure (Shown on screen) Action level Remarks
component gory
Mechanical
1500L0 T/M Clutches Double Engagement TM L04
system
Mechanical
15B0NX T/M Oil Filter Clogging TM L01
system
Mechanical
15F0KM Gear Shifting from R to F Abuse 1 TM -
system
Mechanical
15F0MB Gear Shifting from R to F Abuse 2 TM -
system
Mechanical
15F7KM T/M Clutch Disk Abuse (Forward) TM -
system
Electrical
15G0MW T/M Clutch Slipping (Reverse) TM L03
system
Mechanical
15G7KM T/M Clutch Disk Abuse (Reverse) TM -
system
Electrical
15H0MW T/M Clutch Slipping (High) TM L03
system
Electrical
15J0MW T/M Clutch Slipping (Low) TM L03
system
Electrical
15K0MW T/M Clutch Slipping (1st) TM L03
system
Electrical
15L0MW T/M Clutch Slipping (2nd) TM L03
system
Electrical
15M0MW T/M Clutch Slipping (3rd) TM L03
system
Electrical
15N0MW Clutch System Abnormality (4th) TM L03
system
Electrical
15SBL1 ECMV Release Trouble (Reverse Clutch) TM L03
system
Electrical
15SBMA ECMV Engage Trouble (Reverse Clutch) TM L03
system
Electrical
15SCL1 ECMV Release Trouble (High Clutch) TM L03
system
Electrical
15SCMA ECMV Engage Trouble (High Clutch) TM L03
system
Electrical
15SDL1 ECMV Release Trouble (Low Clutch) TM L03
system
Electrical
15SDMA ECMV Engage Trouble (Low Clutch) TM L03
system
Electrical
15SEL1 ECMV Release Trouble (1st Clutch) TM L03
system
Electrical
15SEMA ECMV Engage Trouble (1st Clutch) TM L03
system
Electrical
15SFL1 ECMV Release Trouble (2nd Clutch) TM L03
system
Electrical
15SFMA ECMV Engage Trouble (2nd Clutch) TM L03
system
HD465-8, HD605-8 40-167

FAILURE CODES TABLE 40 TROUBLESHOOTING

component gory
Electrical
15SGL1 ECMV Release Trouble (3rd Clutch) TM L03
system
Electrical
15SGMA ECMV Engage Trouble (3rd Clutch) TM L03
system
Electrical
15SHL1 ECMV Release Trouble (4th Clutch) TM L03
system
Electrical
15SHMA ECMV Malfunction (4th Clutch) TM L03
system
Electrical
15SJMA ECMV Engage Trouble (Lock Up Clutch) TM L03
system
Mechanical
2C4MNX Brake Cooling Oil Filter Clogging MON L01
system
Mechanical
2F00KM Parking Brake Dragging TM -
system
Mechanical
2G42ZG Accumulator Oil Pressure Low (Front) RHC L03
system
Mechanical
2G43ZG Accumulator Oil Pressure Low (Rear) RHC L03
system
Mechanical
6014NX Hydraulic Oil Filter Clogging MON L01
system
A/C Recirculation Air Temperature Sensor Open Electrical
879AKA MON -
Circuit system
A/C Recirculation Air Temperature Sensor Short Electrical
879AKB MON -
Circuit system
Electrical
879BKA A/C Fresh Air Temperature Sensor Open Circuit MON L01
system
Electrical
879BKB A/C Fresh Air Temperature Sensor Short Circuit MON L01
system
Electrical
879CKA Ventilating Sensor Open Circuit MON -
system
Electrical
879CKB Ventilating Sensor Short Circuit MON -
system
Electrical
879EMC Ventilation Damper Malfunction MON L01
system
Electrical
879FMC Air Mix Damper Malfunction MON L01
system
Electrical
879GKX Refrigerant Pressure Input Signal Out of Range MON L01
system
Mechanical
989D00 Gradient Caution RHC -
system
Electrical
989L00 Engine Controller Lock Caution 1 MON -
system
Electrical
989M00 Engine Controller Lock Caution 2 MON -
system
Electrical
989N00 Engine Controller Lock Caution 3 MON -
system
40-168 HD465-8, HD605-8


component gory
Mechanical
989X00 Overspeed Warning TM -
system
Mechanical
989Y00 Overload Warning TM -
system
Mechanical
A1U0N3 HC Desorb Request 1 ENG L01
system
Mechanical
A1U0N4 HC Desorb Request 2 ENG L03
system
Mechanical
AA10NX Air Cleaner Clogging MON L01
system
Electrical
AB00KE Charge Voltage Low TM L03
system
Electrical
AB00KY Alternator R Terminal Hot Short Circuit TM L03
system
Mechanical
AQ00N3 KDPF System Imbalance Soot Accumulation 1 ENG -
system
Mechanical
AQ00N4 KDPF System Imbalance Soot Accumulation 2 ENG -
system
Manual Stationary Regeneration Request (KDOC Mechanical
AQ10N3 ENG L01
Face Plugging) system
Mechanical
B@BAZG Eng Oil Press Low ENG L03
system
Mechanical
B@BAZK Engine Oil Level Low MON L01
system
Mechanical
B@BCNS Eng Water Overheat ENG L02
system
Mechanical
B@BCQA Engine Coolant Level Low MON L02
system
Mechanical
B@BCZK Engine Coolant Level Low MON L01
system
Mechanical
B@C7NS Retarder Oil Overheat (Rear) MON L02
system
Mechanical
B@CENS Power Train Oil Overheat MON L02
system
Mechanical
B@JANS Steering Oil Overheat RHC L02
system
Electrical
CA115 Engine NE and Backup Speed Sensor Error ENG L04
system
Electrical
CA122 Charge Air Pressure Sensor High Error ENG L03
system
Electrical
CA123 Charge Air Pressure Sensor Low Error ENG L03
system
Electrical
CA131 Throttle Sensor High Error ENG L03
system
Electrical
CA132 Throttle Sensor Low Error ENG L03
system
HD465-8, HD605-8 40-169


component gory
Electrical
CA135 Engine Oil Pressure Sensor High Error ENG L01
system
Electrical
CA141 Engine Oil Pressure Sensor Low Error ENG L01
system
Electrical
CA144 Coolant Temperature Sensor High Error ENG L01
system
Electrical
CA145 Coolant Temperature Sensor Low Error ENG L01
system
Electrical
CA153 Charge Air Temperature Sensor High Error ENG L03
system
Electrical
CA154 Charge Air Temperature Sensor Low Error ENG L03
system
Electrical
CA187 Sensor 2 Supply Voltage Low Error ENG L03
system
Electrical
CA212 Engine Oil Temperature Sensor High Error ENG L01
system
Electrical
CA213 Engine Oil Temperature Sensor Low Error ENG L01
system
Electrical
CA221 Ambient Pressure Sensor High Error ENG L03
system
Electrical
CA222 Ambient Pressure Sensor Low Error ENG L03
system
Electrical
CA227 Sensor 2 Supply Voltage High Error ENG L03
system
Mechanical
CA234 Engine Overspeed ENG L02
system
Electrical
CA238 NE Speed Sensor Supply Voltage Error ENG L01
system
Electrical
CA239 NE Speed Sensor Supply Voltage High Error ENG L01
system
Electrical
CA271 PCV 1 Short Circuit Error ENG L03
system
Electrical
CA272 PCV 1 Open Circuit Error ENG L03
system
Electrical
CA273 PCV 2 Short Circuit Error ENG L03
system
Electrical
CA274 PCV 2 Open Circuit Error ENG L03
system
Injector #1 (L#1) Open Circuit Error or Short Cir- Electrical
CA322 ENG L03
cuit Error system
CA323 ENG L03
cuit Error system
CA324 ENG L03
cuit Error system
CA325 ENG L03
cuit Error system
40-170 HD465-8, HD605-8


component gory
CA331 ENG L03
cuit Error system
CA332 ENG L03
cuit Error system
Electrical
CA343 Engine Controller Internal Abnormality ENG L04
system
Electrical
CA351 Injectors Drive Circuit Error ENG L03
system
Electrical
system
Electrical
CA356 MAF Sensor High Error ENG L03
system
Electrical
CA357 MAF Sensor Low Error ENG L03
system
Electrical
system
Electrical
CA431 Idle Validation SW Error ENG L01
system
Electrical
CA432 Idle Validation Process Error ENG L03
system
Electrical
CA441 Battery Voltage Low Error ENG L04
system
Electrical
CA442 Battery Voltage High Error ENG L04
system
Electrical
CA449 Common Rail Pressure High Error 2 ENG L03
system
Electrical
CA451 Common Rail Pressure Sensor High Error ENG L03
system
Electrical
CA452 Common Rail Pressure Sensor Low Error ENG L03
system
Common Rail Pressure Sensor Supply Voltage Electrical
CA515 ENG L03
High Error system
Common Rail Pressure Sensor Supply Voltage Electrical
CA516 ENG L03
Low Error system
Electrical
CA553 Common Rail Pressure High Error 1 ENG L01
system
Electrical
CA555 Crankcase Pressure High Error 1 ENG L01
system
Electrical
CA556 Crankcase Pressure High Error 2 ENG L03
system
Electrical
CA559 Common Rail Pressure Low Error 1 ENG L01
system
Electrical
CA595 Turbocharger Speed High Error 2 ENG L01
system
Electrical
CA687 Turbocharger Speed Low Error ENG L01
system
HD465-8, HD605-8 40-171


component gory
Electrical
CA689 Engine NE Speed Sensor Error ENG L01
system
Electrical
CA691 Intake Air Temperature Sensor High Error ENG L01
system
Electrical
CA692 Intake Air Temperature Sensor Low Error ENG L01
system
Engine Controller Internal Temperature Sensor Electrical
CA697 ENG L01
High Error system
CA698 ENG L01
Low Error system
Electrical
CA731 Engine Backup Speed Sensor Phase Error ENG L01
system
Electrical
CA778 Engine Backup Speed Sensor Error ENG L01
system
Electrical
CA1117 Engine Controller Partial Data Lost Error ENG L04
system
Electrical
CA1135 CEN Communication Error ENG L03
system
Electrical
CA1257 Multi-controller ID Harness Key Error ENG L03
system
Electrical
CA1664 KDOC Abnormality ENG L03
system
Electrical
CA1691 Defective Regeneration ENG L03
system
Electrical
system
Electrical
system
Electrical
CA1843 Crankcase Pressure Sensor High Error ENG L01
system
Electrical
CA1844 Crankcase Pressure Sensor Low Error ENG L01
system
Electrical
CA1879 KDPF Differential Pressure Sensor High Error ENG L03
system
Electrical
CA1881 KDPF Differential Pressure Sensor Low Error ENG L03
system
KDPF Differential Pressure Sensor In Range Electrical
CA1883 ENG L03
Error system
Mechanical
CA1921 KDPF Soot Accumulation High Error 1 ENG L03
system
Mechanical
CA1922 KDPF Soot Accumulation High Error 2 ENG L04
system
Electrical
CA1923 Fuel Doser Solenoid 1 High Error ENG L03
system
Electrical
CA1924 Fuel Doser Solenoid 1 Low Error ENG L03
system
40-172 HD465-8, HD605-8


component gory
Electrical
CA1925 Fuel Doser Solenoid 1 In Range Error ENG L03
system
Electrical
CA1927 Dosing Fuel Pressure Sensor High Error ENG L01
system
Electrical
CA1928 Dosing Fuel Pressure Sensor Low Error ENG L01
system
Electrical
CA1942 Crankcase Pressure Sensor In Range Error ENG L01
system
Electrical
CA1963 Fuel Doser Solenoid 1 Servo Error ENG L03
system
Electrical
CA1977 Fuel Doser Open Error or Short Error ENG L03
system
Electrical
CA1993 KDPF Differential Pressure Low Error ENG L03
system
Electrical
CA2185 Throttle Sensor Supply Voltage High Error ENG L03
system
Electrical
CA2186 Throttle Sensor Supply Voltage Low Error ENG L03
system
Electrical
CA2249 Common Rail Pressure Low Error 2 ENG L03
system
Electrical
CA2265 Fuel Feed Pump Open Error ENG L01
system
Electrical
CA2266 Fuel Feed Pump Short Error ENG L01
system
Electrical
CA2271 EGR Valve Position Sensor High Error ENG L03
system
Electrical
CA2272 EGR Valve Position Sensor Low Error ENG L03
system
Electrical
CA2349 EGR Valve Solenoid Open Circuit Error ENG L03
system
Electrical
CA2353 EGR Valve Solenoid Short Circuit Error ENG L03
system
Electrical
CA2357 EGR Valve Servo Error ENG L03
system
Electrical
CA2381 VGT Position Sensor High Error ENG L03
system
Electrical
CA2382 VGT Position Sensor Low Error ENG L03
system
Electrical
CA2383 VGT Solenoid Open Circuit Error ENG L03
system
Electrical
CA2386 VGT Solenoid Short Circuit Error ENG L03
system
Electrical
CA2387 VGT Servo Error ENG L03
system
Electrical
CA2555 Intake Air Heater Relay Open Circuit Error ENG L01
system
HD465-8, HD605-8 40-173


component gory
Electrical
CA2556 Intake Air Heater Relay Short Circuit Error ENG L01
system
Electrical
CA2637 KDOC Face Plugging ENG L01
system
Mechanical
CA2639 Manual Stationary Regeneration Request ENG L01
system
Electrical
CA2732 Fuel Doser Solenoid 2 High Error ENG L03
system
Electrical
CA2733 Fuel Doser Solenoid 2 Low Error ENG L03
system
Electrical
CA2741 Fuel Dozer Solenoid Valve Swap Error ENG L03
system
Electrical
CA2765 Injector Trim Data Mismatch ENG L01
system
Manual Stationary Regeneration Request but Electrical
CA2777 ENG -
KDPF Regeneration Disable system
Electrical
CA2878 Fuel Doser Solenoid 2 Servo Error ENG L03
system
Electrical
CA2881 Dosing Fuel Pressure Low Error 1 ENG L03
system
Electrical
CA3133 KDPF Outlet Pressure Sensor High Error ENG L03
system
Electrical
CA3134 KDPF Outlet Pressure Sensor Low Error ENG L03
system
Electrical
CA3135 KDPF Outlet Pressure Sensor In Range Error ENG L03
system
Electrical
CA3167 Fuel Doser Degradation ENG -
system
Electrical
CA3251 KDOC Inlet Temperature High Error ENG L03
system
Electrical
CA3253 KDOC Temperature Error - Non Regeneration ENG L03
system
Electrical
CA3254 KDOC Outlet Temperature High Error 1 ENG L01
system
Electrical
CA3255 KDPF Temperature Error - Non Regeneration ENG L03
system
Electrical
CA3256 KDPF Outlet Temperature High Error 1 ENG L01
system
Electrical
CA3311 KDOC Outlet Temperature High Error 2 ENG L03
system
Electrical
CA3312 KDPF Outlet Temperature High Error 2 ENG L03
system
Electrical
CA3313 KDOC Inlet Temperature Sensor Low Error ENG L03
system
Electrical
CA3314 KDOC Inlet Temperature Sensor High Error ENG L03
system
40-174 HD465-8, HD605-8


component gory
Electrical
CA3315 KDOC Inlet Temperature Sensor In Range Error ENG L03
system
Electrical
CA3316 KDOC Outlet Temperature Sensor Low Error ENG L03
system
Electrical
CA3317 KDOC Outlet Temperature Sensor High Error ENG L03
system
Electrical
CA3318 KDOC Outlet Temperature Sensor In Range Error ENG L03
system
Electrical
CA3319 KDPF Outlet Temperature Sensor High Error ENG L03
system
Electrical
CA3321 KDPF Outlet Temperature Sensor Low Error ENG L03
system
Electrical
CA3322 KDPF Outlet Temperature Sensor In Range Error ENG L03
system
Electrical
CA3419 MAF Sensor Supply Voltage High Error ENG L03
system
Electrical
CA3421 MAF Sensor Supply Voltage Low Error ENG L03
system
KDOC and KDPF Temperature Sensor Datalink Electrical
CA4151 ENG L03
Timeout Error system
KDOC and KDPF Temperature Sensor Internal Electrical
CA4158 ENG L03
Circuit Error system
KDOC and KDPF Temperature Sensor ECU Volt- Electrical
CA4161 ENG L03
age High Error system
CA4162 ENG L03
age Low Error system
KDOC and KDPF Temperature Sensor ECU Over Electrical
CA4163 ENG L01
Temperature Error system
KDOC and KDPF Temperature Sensor Power Electrical
CA4259 ENG L03
Interrupt Error system
System Operating Lamp Short Circuit (Engine Electrical
CA4952 ENG -
Controller) system
Electrical
CA5383 Ash Accumulation High Error ENG -
system
Electrical
CB115 Engine NE and Backup Speed Sensor Error_2 ENG L04
system
Electrical
CB187 Sensor Supply_2 Voltage Low Error_2 ENG L03
system
Electrical
CB227 Sensor Supply_2 Voltage High Error_2 ENG L03
system
Electrical
CB238 NE Speed Sensor Supply Voltage Error_2 ENG L01
system
Electrical
CB239 NE Speed Sensor Supply Voltage High Error_2 ENG L01
system
Electrical
CB271 IMV or PCV 1 Short Circuit Error_2 ENG L03
system
HD465-8, HD605-8 40-175


component gory
Electrical
CB272 IMV or PCV 1 Open Circuit Error_2 ENG L03
system
Electrical
CB273 PCV_2 Short Circuit Error_2 ENG L03
system
Electrical
CB274 PCV_2 Open Circuit Error_2 ENG L03
system
Electrical
CB343 Engine Controller Internal Abnormality_2 ENG L04
system
Electrical
CB352 Sensor Supply 1 Voltage Low Error_2 ENG L03
system
Electrical
CB386 Sensor Supply 1 Voltage High Error_2 ENG L03
system
Electrical
CB441 Power Voltage Low Error_2 ENG L04
system
Electrical
CB442 Power Voltage High Error_2 ENG L04
system
Electrical
CB689 Engine NE Speed Sensor Error_2 ENG L01
system
CB697 ENG L01
High Error_2 system
CB698 ENG L01
Low Error_2 system
Electrical
CB731 Engine Backup Speed Sensor Phase Error_2 ENG L01
system
Electrical
CB778 Engine Backup Speed Sensor Error_2 ENG L01
system
Electrical
CB1117 Engine Controller Partial Data Lost Error_2 ENG L04
system
Electrical
CB1257 Multi-controller ID Harness Key Error_2 ENG L03
system
Electrical
CB1664 KDOC Abnormality_2 ENG L03
system
Electrical
CB1691 Defective Regeneration_2 ENG L03
system
Electrical
CB1695 Sensor Supply 5 Voltage High Error_2 ENG L03
system
Electrical
CB1696 Sensor Supply 5 Voltage Low Error_2 ENG L03
system
Electrical
CB1879 KDPF Differential Pressure Sensor High Error_2 ENG L03
system
Electrical
CB1881 KDPF Differential Pressure Sensor Low Error_2 ENG L03
system
KDPF Differential Pressure Sensor In Range Electrical
CB1883 ENG L03
Error_2 system
Mechanical
CB1921 KDPF Soot Accumulation High Error 1_2 ENG L03
system
40-176 HD465-8, HD605-8


component gory
Mechanical
CB1922 KDPF Soot Accumulation High Error 2_2 ENG L04
system
Electrical
CB1923 Fuel Doser Solenoid 1 High Error_2 ENG L03
system
Electrical
CB1924 Fuel Doser Solenoid 1 Low Error_2 ENG L03
system
Electrical
CB1925 Fuel Doser Solenoid 1 In Range Error_2 ENG L03
system
Electrical
CB1927 Dosing Fuel Pressure Sensor High Error_2 ENG L01
system
Electrical
CB1928 Dosing Fuel Pressure Sensor Low Error_2 ENG L01
system
Electrical
CB1963 Fuel Doser Solenoid 1 Servo Error_2 ENG L03
system
Fuel Doser Open Circuit Error or Short Circuit Electrical
CB1977 ENG L03
Error_2 system
Electrical
CB1993 KDPF Differential Pressure Low Error_2 ENG L03
system
Electrical
CB2265 Fuel Feed Pump Open Circuit Error_2 ENG L01
system
Electrical
CB2266 Fuel Feed Pump Short Circuit Error_2 ENG L01
system
Electrical
CB2637 KDOC Face Plugging_2 ENG L01
system
Mechanical
CB2639 Manual Stationary Regeneration Request_2 ENG L01
system
Electrical
CB2732 Fuel Doser Solenoid_2 High Error_2 ENG L03
system
Electrical
CB2733 Fuel Doser Solenoid_2 Low Error_2 ENG L03
system
Electrical
CB2741 Fuel Dozer Solenoid Valve Swap Error_2 ENG L03
system
Manual Stationary Regeneration Request but Electrical
CB2777 ENG -
KDPF Regeneration Disable_2 system
Electrical
CB2878 Fuel Doser Solenoid_2 Servo Error_2 ENG L03
system
Electrical
CB2881 Dosing Fuel Pressure Low Error 1_2 ENG L03
system
Electrical
CB3133 KDPF Outlet Pressure Sensor High Error_2 ENG L03
system
Electrical
CB3134 KDPF Outlet Pressure Sensor Low Error_2 ENG L03
system
Electrical
CB3135 KDPF Outlet Pressure Sensor In Range Error_2 ENG L03
system
Electrical
CB3167 Fuel Doser Degradation_2 ENG -
system
HD465-8, HD605-8 40-177


component gory
Electrical
CB3251 KDOC Inlet Temperature High Error_2 ENG L03
system
Electrical
CB3253 KDOC Temperature Error - Non Regeneration_2 ENG L03
system
Electrical
CB3254 KDOC Outlet Temperature High Error 1_2 ENG L01
system
Electrical
CB3255 KDPF Temperature Error - Non Regeneration_2 ENG L03
system
Electrical
CB3256 KDPF Outlet Temperature High Error 1_2 ENG L01
system
Electrical
CB3311 KDOC Outlet Temperature High Error 2_2 ENG L03
system
Electrical
CB3312 KDPF Outlet Temperature High Error 2_2 ENG L03
system
Electrical
CB3313 KDOC Inlet Temperature Sensor Low Error_2 ENG L03
system
Electrical
CB3314 KDOC Inlet Temperature Sensor High Error_2 ENG L03
system
KDOC Inlet Temperature Sensor In Range Electrical
CB3315 ENG L03
Error_2 system
Electrical
CB3316 KDOC Outlet Temperature Sensor Low Error_2 ENG L03
system
Electrical
CB3317 KDOC Outlet Temperature Sensor High Error_2 ENG L03
system
KDOC Outlet Temperature Sensor In Range Electrical
CB3318 ENG L03
Error_2 system
Electrical
CB3319 KDPF Outlet Temperature Sensor High Error_2 ENG L03
system
Electrical
CB3321 KDPF Outlet Temperature Sensor Low Error_2 ENG L03
system
KDPF Outlet Temperature Sensor In Range Electrical
CB3322 ENG L03
Error_2 system
KDOC and KDPF Temperature Sensor Datalink Electrical
CB4151 ENG L03
Timeout Error_2 system
KDOC/KDPF Temp Sensor Internal Circuit Electrical
CB4158 ENG L03
Error_2 system
CB4161 ENG L03
age High Error_2 system
CB4162 ENG L03
age Low Error_2 system
KDOC and KDPF Temperature Sensor ECU Over Electrical
CB4163 ENG L01
Temperature Error_2 system
KDOC and KDPF Temperature Sensor Power Electrical
CB4259 ENG L03
Interrupt Error_2 system
Electrical
CB4952 Operating Lamp Short Circuit (ENG Con)_2 ENG -
system
40-178 HD465-8, HD605-8


component gory
Electrical
CB5383 Ash Accumulation High Error_2 ENG -
system
Secondary Steering Motor Relay Output Ground Electrical
D150KB RHC L03
Fault system
Secondary Steering Motor Relay Output Open Electrical
D150KZ RHC L03
Circuit or Hot Short Circuit system
Electrical
D164KY Head Light High Select Relay Hot Short Circuit MON L01
system
Stop Lamp Relay Output Open Circuit or Hot Electrical
D19HKZ RHC L01
Short Circuit (Right & Left) system
Personal Code Relay Output Open Circuit or Electrical
D19JKZ MON L03
Ground Fault system
Electrical
D19QKZ Stop Lamp (Center) Output System Abnormality RHC L01
system
Electrical
D1EHKA Engine Start Relay Output Open Circuit TM L03
system
Electrical
D1EHKB Engine Start Relay Output Ground Fault TM L03
system
Electrical
D1EHKY Engine Start Relay Output Hot Short Circuit TM L03
system
Parking Brake Interlock Relay Output Open Cir- Electrical
D1EMKA RHC L03
cuit system
Parking Brake Interlock Relay Output Ground Electrical
D1EMKB RHC L03
Fault system
Parking Brake Interlock Relay Output Hot Short Electrical
D1EMKY RHC L03
Circuit system
Electrical
D1FBKB Solenoid Self-Holding Relay Output Ground Fault TM L03
system
Electrical
D5ZHL6 Key SW C Terminal Signal Mismatch MON L01
system
Electrical
D5ZKKZ Front Brake Cut Valve System Abnormality RHC L01
system
Electrical
D862KA GPS Antenna Open Circuit KOMTRAX -
system
Electrical
DAF0KT Monitor Nonvolatile Memory Abnormality MON L03
system
Electrical
DAF0MB Monitor ROM Abnormality MON -
system
Electrical
DAF0MC Monitor Malfunction MON -
system
Electrical
DAF3KK Monitor Power Voltage Low Error MON -
system
Electrical
DAF8KB Camera Power Supply Short Circuit MON L03
system
12V Power Output Hot Short or Ground Fault Electrical
DAFDKB MON L01
(Monitor) system
HD465-8, HD605-8 40-179


component gory
Electrical
DAFGMC GPS Module Malfunction KOMTRAX -
system
Electrical
DAFLKA System Operating Lamp Open Circuit (Monitor) MON -
system
Electrical
DAFLKB System Operating Lamp Short Circuit (Monitor) MON -
system
Electrical
DAFQKR CAN 2 Defective Communication (Monitor) KOMTRAX -
system
Electrical
DAQ0KK Main Power Voltage Low Error (T/M Controller) TM L03
system
Electrical
DAQ0KT T/M Controller Read Only Memory Abnormality TM L01
system
Electrical
DAQ0MC T/M Controller Malfunction TM -
system
Key SW ACC Main Power Supply Open Circuit Electrical
DAQ1KA TM L03
(T/M Controller) system
Solenoid Power Voltage Low Error (T/M Control- Electrical
DAQ2KK TM L03
ler) system
Electrical
DAQ9KQ Model Selection Signal Mismatch (T/M Controller) TM L03
system
System Operating Lamp Open Circuit (T/M Con- Electrical
DAQLKA TM -
troller) system
System Operating Lamp Short Circuit (T/M Con- Electrical
DAQLKB TM -
troller) system
Electrical
DAQQKR CAN2 Defective Communication (T/M Controller) MON L03
system
Electrical
DAQRKR CAN1 Defective Communication (T/M Controller) MON L03
system
Electrical
DAQRMA Option Selection Inconsistency (T/M Controller) TM L03
system
Mechanical
DAQV00 Neutral Coast Caution TM -
system
Mechanical
DAQW00 Neutral Over Speed Caution TM -
system
Electrical
DAZ9KQ Model Selection Signal Mismatch (A/C) MON -
system
Electrical
DAZQKR CAN 2 Defective Communication (A/C ECU) MON L01
system
Electrical
DB10KT RHC Read Only Memory Abnormality RHC L01
system
Electrical
DB10MC RHC Malfunction RHC -
system
Electrical
DB11KA Key SW ACC Signal Open Circuit (RHC) RHC L03
system
Key SW ACC Signal Open Circuit (RHC) (For
Electrical
DB11KA machines equipped with emergency engine stop RHC L03
system
switch)
40-180 HD465-8, HD605-8


component gory
Electrical
DB12KK Solenoid Power Voltage Low Error (RHC) RHC L03
system
Electrical
DB13KK Main Power Voltage Low Error (RHC) RHC L03
system
Electrical
DB19KQ Model Selection Signal Mismatch (RHC) RHC L03
system
Electrical
DB1LKA System Operating Lamp Open Circuit (RHC) RHC -
system
Electrical
DB1LKB System Operating Lamp Short Circuit (RHC) RHC -
system
Electrical
DB1QKR CAN 2 Defective Communication (RHC) MON L03
system
Electrical
DB1QMA Option Selection Inconsistency (RHC) RHC L03
system
Electrical
DB1RKR CAN 1 Defective Communication (RHC) MON L03
system
CAN 2 Defective Communication (Engine Control- Electrical
DB2QKR MON L03
ler) system
DB2QKR MON L03
ler) system
DB2RKR MON L03
ler) system
DB2RKR MON L03
ler) system
Non-volatile Memory (ABS Controller) Abnormal- Electrical
DBC0KT ABS L01
ity system
Electrical
DBC0MC ABS Controller Error ABS -
system
Key Switch ACC terminal (ABS Controller) Dis- Electrical
DBC1KA ABS L03
connection system
Drop in Anti-skid Brake System Controller Sole- Electrical
DBC2KK ABS L03
noid Power Source system
Drop in ABS Controller Battery Direct Power Electrical
DBC3KK ABS L03
Source system
Electrical
DBC9KQ Model Selection (ABS Controller) Inconsistency ABS L03
system
System Operating Lamp (ABS Controller) Discon- Electrical
DBCLKA ABS -
nection system
System Operating Lamp (ABS Controller) Short Electrical
DBCLKB ABS -
Circuit system
Electrical
DBCQKR CAN2 Defective Communication (ABS Controller) MON L03
system
Electrical
DBCRKR CAN1 Defective Communication (ABS Controller) MON L03
system
Electrical
DBCQMA Option Selection (ABS Controller) Inconsistency ABS L03
system
HD465-8, HD605-8 40-181


component gory
Electrical
DBV0MC KOMTRAX Plus Malfunction KOMTRAX -
system
Controller Power Supply Voltage Low (KOMTRAX Electrical
DBV1KK KOMTRAX L01
Plus) system
24V Sensor Power Voltage System Ground Fault Electrical
DBV6KB KOMTRAX L01
(KOMTRAX Plus) system
12V Sensor Power Voltage System Ground Fault Electrical
DBV7KB KOMTRAX L01
(KOMTRAX Plus) system
System Operating Lamp Open Circuit (KOMTRAX Electrical
DBVLKA KOMTRAX -
Plus) system
System Operating Lamp Short Circuit (KOMTRAX Electrical
DBVLKB KOMTRAX -
Plus) system
CAN2 Defective Communication (KOMTRAX Electrical
DBVQKR MON L01
Plus) system
CAN1 Defective Communication (KOMTRAX Electrical
DBVRKR MON L01
Plus) system
Electrical
DBVVKR LAN 1 Defective Communication KOMTRAX -
system
Electrical
DBVWKR LAN 2 Defective Communication KOMTRAX -
system
Electrical
DDAAL6 Engine Shutdown Secondary Switch Open Circuit MON L03
system
Engine Shutdown Secondary Switch Open Circuit
Electrical
DDAAL6 (For machines equipped with emergency engine MON L03
system
stop switch)
Electrical
DDACL4 Machine Lockout Switch Failure TM L03
system
Electrical
DDADKA Machine Lockout Work Lamp Failure TM L03
system
Electrical
DDADKY Machine Lockout Work Lamp Hot Short TM L03
system
Electrical
DDD7KX Travel Speed Setting Switch System Abnormality RHC L03
system
Electrical
DDP6L4 Service brake pressure switch Malfunction ABS L03
system
Electrical
DDTHKA Fill Switch Open Circuit (High Clutch) TM L01
system
Electrical
DDTJKA Fill Switch Open Circuit (Low Clutch) TM L01
system
Electrical
DDTKKA Fill Switch Open Circuit (1st Clutch) TM L01
system
Electrical
DDTLKA Fill Switch Open Circuit (2nd Clutch) TM L01
system
Electrical
DDTMKA Fill Switch Open Circuit (3rd Clutch) TM L01
system
Electrical
DDTNKA Fill Switch Open Circuit (Reverse Clutch) TM L01
system
40-182 HD465-8, HD605-8


component gory
Electrical
DDTPKA Fill Switch Open Circuit (4th Clutch) TM L01
system
Electrical
DF10KA T/M Shift Lever Input Signal Open Circuit TM L03
system
Electrical
DF10KB T/M Shift Lever Input Signal Short Circuit TM L03
system
Electrical
DGE5KX Ambient Air Temp Sensor Signal Out of Range KOMTRAX -
system
T/M Oil Temperature Sensor Input Signal Out of Electrical
DGF1KX TM L03
Range system
Retarder Oil Temperature Sensor Ground Fault Electrical
DGR2KB RHC L01
(Rear) system
Electrical
DGR6KB Steering Oil Temperature Sensor Ground Fault RHC L01
system
Steering Oil Temperature Sensor Open Circuit or Electrical
DGR6L8 RHC L01
Hot Short Circuit system
T/C Oil Temperature Sensor Input Signal Out of Electrical
DGT1KX TM L01
Range system
Electrical
DGT4KA Exhaust Temperature Sensor Open Circuit Fault KOMTRAX -
system
Applied to
Electrical machine for
DGT4KB Exhaust Temperature Sensor Ground Fault KOMTRAX -
system serial number
30112 or less
Applied to
Electrical machine for
DGT4KY Exhaust Temperature Sensor Hot Short KOMTRAX -
system serial number
30113 and up
Electrical
DHA4KA Air Cleaner Clogging Sensor Open Circuit MON L01
system
Electrical
DHAAMA KDPF Differential Pressure Sensor Frozen ENG -
system
Electrical
DHABMA KDPF Differential Pressure Sensor Frozen_2 ENG -
system
Electrical
DHACMA KDPF Outlet Pressure Sensor Frozen ENG -
system
Electrical
DHADMA KDPF Outlet Pressure Sensor Frozen_2 ENG -
system
Suspension Pressure Sensor Hot Short Circuit Electrical
DHP4KY KOMTRAX L01
(Front Right) system
Suspension Pressure Sensor Open Circuit or Electrical
DHP4KZ KOMTRAX L01
Ground Fault (Front Right) system
DHP5KY KOMTRAX L01
(Front Left) system
DHP5KZ KOMTRAX L01
Ground Fault (Front Left) system
Suspension Pressure Sensor Signal Out of Electrical
DHP6KA RHC L01
Range (Rear Right) system
HD465-8, HD605-8 40-183


component gory
DHP6KX RHC L03
Range (Rear Right) system
DHP6KY KOMTRAX L01
(Rear Right) system
DHP6KZ KOMTRAX L01
Ground Fault (Rear Right) system
DHP7KA RHC L01
Range (Rear Left) system
DHP7KX RHC L03
Range (Rear Left) system
DHP7KY KOMTRAX L01
(Rear Left) system
DHP7KZ KOMTRAX L01
Ground Fault (Rear Left) system
Main Flow Select Valve Pressure Sensor Input Electrical
DHQ2KX TM L01
Signal Out of Range system
Main Pressure Variable Valve Pressure Sensor Electrical
DHQ4KX TM L01
Input Signal Out of Range system
T/C Oil Pressure Sensor Input Signal Out of Electrical
DHT5KX TM L01
Range system
Electrical
DHT5L6 T/C Oil Pressure Sensor Input Signal Mismatch TM L01
system
S/T Oil Pressure Sensor Input Signal Out of Electrical
DHT8KX RHC L01
Range system
Mechanical
DHT8ZG S/T Oil Pressure Low RHC L03
system
Accumulator Oil Pressure Sensor Input Signal Electrical
DHU2KX RHC L01
Out of Range (Front) system
Accumulator Oil Pressure Sensor Input Signal Electrical
DHU3KX RHC L01
Out of Range (Rear) system
ABS control valve pressure sensor (Front Right) Electrical
DHU6KX ABS L03
circuit Abnormality system
ABS control valve pressure sensor (Front Left) cir- Electrical
DHU7KX ABS L03
cuit Abnormality system
ABS control valve pressure sensor (Rear Right) Electrical
DHU8KX ABS L03
circuit Abnormality system
ABS control valve pressure sensor (Rear Left) cir- Electrical
DHU9KX ABS L03
cuit Abnormality system
Parking Brake Pressure Sensor Input Signal Out Electrical
DHUCKX RHC L01
of Range system
Secondary S/T Pressure Sensor 1 Input Signal Electrical
DHUDKX RHC L01
Out of Range system
Secondary Brake Pressure Sensor Signal Out of Electrical
DHUHKX RHC L01
Range system
KTCS Pressure Sensor Signal Out of Range Electrical
DHULKX RHC L01
(Rear Right) system
40-184 HD465-8, HD605-8


component gory
KTCS Pressure Sensor Signal Out of Range Electrical
DHUMKX RHC L01
(Rear Left) system
Retarder Pressure Sensor Signal Out of Range Electrical
DHUPKX RHC L01
(Rear) system
Electrical
DHUTKX ABS Cut valve pressure sensor Abnormality ABS L03
system
Steering/Hoist Pump Oil Pressure Sensor Out of Electrical
DHY9KX TM L03
Range system
Electrical
DJF1KA Fuel Level Sensor Open Circuit MON L01
system
Steering Angle Potentiometer Input Signal Out of Electrical
DK30KX RHC L01
Range system
Retarder Lever Potentiometer Input Signal and Electrical
DK51L5 RHC L03
RVS Signal Mismatch system
Hoist Lever Potentiometer Input Signal Out of Electrical
DK52KX RHC L03
Range system
Hoist Lever Potentiometer 1 or 2 Signal Abnor- Electrical
DK53L8 RHC L03
mality system
Electrical
DK54KX Body Positioner Sensor Input Signal Out of Range RHC L03
system
Electrical
DK60KX Acceleration Sensor Input Signal Out of Range RHC L01
system
Steering Angle Speed Sensor System Abnormal- Electrical
DKD0L6 RHC L01
ity system
Inclination Angle Sensor Input Signal Out of Electrical
DKH0KX RHC L01
Range (Lateral) system
Inclination Angle Sensor Input Signal Out of Electrical
DKH1KX KOMTRAX L01
Range (Longitudinal) system
Electrical
DLF1KA T/M Input Speed Sensor Open Circuit TM L03
system
T/M Input Speed Sensor Hot Short Circuit or Electrical
DLF1LC TM L03
Ground Fault system
Electrical
DLF2KA T/M Intermediate Speed Sensor Open Circuit TM L03
system
T/M Intermediate Speed Sensor Hot Short Circuit Electrical
DLF2LC TM L03
or Ground Fault system
Electrical
DLF6KA Wheel Speed Sensor (Front Right) Disconnection ABS L03
system
Electrical
DLF6L3 Wheel Speed Sensor (Front Right) Malfunction ABS L03
system
Electrical
DLF7KA Wheel Speed Sensor (Front Left) Disconnection ABS L03
system
Electrical
DLF7L3 Wheel Speed Sensor (Front Left) Malfunction ABS L03
system
Electrical
DLF8KA Wheel Speed Sensor Open Circuit (Rear Right) RHC L01
system
HD465-8, HD605-8 40-185


component gory
Electrical
DLF8L3 Wheel Speed Sensor (Rear Right) Malfunction ABS L03
system
Wheel Speed Sensor System Abnormality (Rear Electrical
DLF8LC RHC L01
Right) system
Electrical
DLF8MA Wheel Speed Sensor (Rear Right) Disconnection ABS L03
system
Electrical
DLF9KA Wheel Speed Sensor Open Circuit (Rear Left) RHC L01
system
Electrical
DLF9L3 Wheel Speed Sensor (Rear Left) Malfunction ABS L03
system
Wheel Speed Sensor System Abnormality (Rear Electrical
DLF9LC RHC L01
Left) system
Electrical
DLF9MA Wheel Speed Sensor (Rear Left) Disconnection ABS L03
system
Radiator Fan Speed Sensor Open Circuit or Hot Electrical
DLM3KA TM L01
Short Circuit system
Electrical
DLM3LC Radiator Fan Speed Sensor Signal Abnormality TM L01
system
Radiator Fan Speed Sensor Function Deteriora- Electrical
DLM3MB TM L01
tion system
Electrical
DLT3KA T/M Output Speed Sensor Open Circuit TM L03
system
T/M Output Speed Sensor Open Circuit or Short Electrical
DLT3LC RHC L01
Circuit system
Electrical
DPQ1KR LIN Defective Communication (Switch Panel) MON L01
system
Electrical
DPQ2KR LIN Defective Communication (LED Unit) MON L01
system
Electrical
DPQ3KR LIN Defective Communication (Rearview Monitor) MON L01
system
Electrical
DSJ0KR CAN 2 Defective Communication (Meter Unit) MON L01
system
Electrical
DV00KB Buzzer Output Circuit Ground Fault MON L01
system
Main Pressure Variable Solenoid Output Open Electrical
DW2AKA TM L01
Circuit system
Main Pressure Variable Solenoid Output Ground Electrical
DW2AKB TM L01
Fault system
Main Pressure Variable Solenoid Output Hot Electrical
DW2AKY TM L01
Short Circuit system
Electrical
DW2AL1 Main Pressure Variable Valve Release Trouble TM L01
system
Electrical
DW2ALH Main Pressure Variable Valve Malfunction TM L01
system
Electrical
DW2BKA Main Flow Selector Solenoid Open Circuit TM L01
system
40-186 HD465-8, HD605-8


component gory
Electrical
DW2BKB Main Flow Selector Solenoid Ground Fault TM L01
system
Electrical
DW2BKY Main Flow Selector Solenoid Hot Short Circuit TM L01
system
Electrical
DW2BL1 Main Flow Selector Valve Release Trouble TM L01
system
Electrical
DW2BLH Main Flow Selector Valve Operation Malfunction TM L01
system
Auto Suspension Solenoid 1 Output System Electrical
DW35KZ RHC L01
Abnormality system
Auto Suspension Solenoid 2 Output System Electrical
DW36KZ RHC L01
Abnormality system
Electrical
DW4BK4 Parking Brake Valve Release Trouble RHC L03
system
Electrical
DW4BMA Parking Brake Valve Activity Malfunction RHC L03
system
Electrical
DW72KZ Dump Lever Kick out Solenoid Malfunction RHC L01
system
Electrical
DW73KA Hoist Selector Solenoid Open Circuit RHC L03
system
Electrical
DW73KB Hoist Selector Solenoid Ground Fault RHC L03
system
Electrical
DW73KY Hoist Selector Solenoid Hot Short Circuit RHC L03
system
Electrical
DW78KZ Brake Cooling Valve Solenoid Malfunction (Rear) RHC L01
system
Electrical
DW7BKB Radiator Fan Reverse Solenoid Ground Fault TM L01
system
Electrical
DW7BKY Radiator Fan Reverse Solenoid Hot Short Circuit TM L01
system
Radiator Fan Reverse Solenoid Open Circuit or Electrical
DW7BKZ TM L01
Hot Short Circuit system
Electrical
DW7NKZ S/T Pump Selector Solenoid Malfunction RHC L01
system
Electrical
DWD6KA Steering Pump Lockout Solenoid Failure TM L03
system
Electrical
DWD6KB Steering Pump Lockout Solenoid Ground Fault TM L03
system
Electrical
DWD6KY Steering Pump Lockout Solenoid Hot Short TM L03
system
Electrical
DWD6MA Steering Pump Lockout Solenoid Malfunction TM L03
system
Steering/Hoist Pump Lockout Solenoid becomes Electrical
DWD7K4 TM L03
stuck system
Electrical
DWD7KA Steering/Hoist Pump Lockout Solenoid Failure TM L03
system
HD465-8, HD605-8 40-187


component gory
Steering/Hoist Pump Lockout Solenoid Ground Electrical
DWD7KB TM L03
Fault system
Electrical
DWD7KY Steering/Hoist Pump Lockout Solenoid Hot Short TM L03
system
Steering/Hoist Pump Lockout Solenoid Malfunc- Electrical
DWD7MA TM L03
tion system
Electrical
DWNDKZ ABS Cut valve solenoid (Front) circuit Abnormality ABS L03
system
Electrical
DWNDMA ABS Cut valve solenoid (Front) Abnormality ABS L03
system
Electrical
DWNEKZ ABS Cut valve solenoid (Rear) circuit Abnormality ABS L03
system
Electrical
DWNEMA ABS Cut valve solenoid (Rear) Abnormality ABS L03
system
Electrical
DWNMKZ Shut off Valve Output System Abnormality RHC L01
system
Electrical
DX11K4 Retarder Valve Release Trouble (Rear) RHC L03
system
Electrical
DX11KA Retarder Valve Output Open Circuit (Rear) RHC L03
system
Electrical
DX11KB Retarder Valve Output Ground Fault (Rear) RHC L03
system
Electrical
DX11KY Retarder Valve Output Hot Short Circuit (Rear) RHC L03
system
Electrical
DX11MA Retarder Valve Malfunction (Rear) RHC L03
system
Electrical
DX13KA Hoist EPC Solenoid Open Circuit RHC L03
system
Electrical
DX13KB Hoist EPC Solenoid Ground Fault RHC L03
system
Electrical
DX13KY Hoist EPC Solenoid Hot Short Circuit RHC L03
system
Electrical
DX16KA Radiator Fan Pump EPC Solenoid Open Circuit TM L03
system
Electrical
DX16KB Radiator Fan Pump EPC Solenoid Ground Fault TM L03
system
Radiator Fan Pump EPC Solenoid Hot Short Cir- Electrical
DX16KY TM L01
cuit system
ABS control valve solenoid (Front Right) Discon- Electrical
DX21KA ABS L03
nection system
ABS control valve solenoid (Front Right) Ground Electrical
DX21KB ABS L03
fault system
Electrical
DX21KY ABS control valve solenoid (Front Right) Hot short ABS L03
system
ABS control valve solenoid (Front Right) circuit Electrical
DX21MA ABS L03
Abnormality system
40-188 HD465-8, HD605-8


component gory
ABS control valve solenoid (Front Left) Discon- Electrical
DX22KA ABS L03
nection system
ABS control valve solenoid (Front Left) Ground Electrical
DX22KB ABS L03
fault system
Electrical
DX22KY ABS control valve solenoid (Front Left) Hot short ABS L03
system
ABS control valve solenoid (Front Left) circuit Electrical
DX22MA ABS L03
Abnormality system
ABS control valve solenoid (Rear Right) Discon- Electrical
DX23KA ABS L03
nection system
ABS control valve solenoid (Rear Right) Ground Electrical
DX23KB ABS L03
fault system
Electrical
DX23KY ABS control valve solenoid (Rear Right) Hot short ABS L03
system
ABS control valve solenoid (Rear Right) circuit Electrical
DX23MA ABS L03
Abnormality system
ABS control valve solenoid (Rear Left) Discon- Electrical
DX24KA ABS L03
nection system
ABS control valve solenoid (Rear Left) Ground Electrical
DX24KB ABS L03
fault system
Electrical
DX24KY ABS control valve solenoid (Rear Left) Hot short ABS L03
system
ABS control valve solenoid (Rear Left) circuit Electrical
DX24MA ABS L03
Abnormality system
ABS control valve solenoid (Front) circuit Abnor- Electrical
DX25MA ABS L03
mality system
ABS control valve solenoid (Rear) circuit Abnor- Electrical
DX26MA ABS L03
mality system
KTCS EPC Solenoid Release Trouble (Rear Electrical
DX37K4 RHC L01
Right) system
KTCS EPC Solenoid Output Open Circuit (Rear Electrical
DX37KA RHC L01
Right) system
KTCS EPC Solenoid Output Ground Fault (Rear Electrical
DX37KB RHC L01
Right) system
KTCS EPC Solenoid Output Hot Short Circuit Electrical
DX37KY RHC L01
(Rear Right) system
Electrical
DX37MA KTCS EPC Solenoid Malfunction (Rear Right) RHC L01
system
Electrical
DX38K4 KTCS EPC Solenoid Release Trouble (Rear Left) RHC L01
system
KTCS EPC Solenoid Output Open Circuit (Rear Electrical
DX38KA RHC L01
Left) system
KTCS EPC Solenoid Output Ground Fault (Rear Electrical
DX38KB RHC L01
Left) system
KTCS EPC Solenoid Output Hot Short Circuit Electrical
DX38KY RHC L01
(Rear Left) system
HD465-8, HD605-8 40-189


component gory
Electrical
DX38MA KTCS EPC Solenoid Malfunction (Rear Left) RHC L01
system
Electrical
DXH1KA ECMV Solenoid Open Circuit (Lock Up Clutch) TM L03
system
Electrical
DXH1KB ECMV Solenoid Ground Fault (Lock Up Clutch) TM L03
system
ECMV Solenoid Hot Short Circuit (Lock Up Electrical
DXH1KY TM L03
Clutch) system
Electrical
DXH2KA ECMV Solenoid Open Circuit (High) TM L03
system
Electrical
DXH2KB ECMV Solenoid Ground Fault (High) TM L03
system
Electrical
DXH2KY ECMV Solenoid Hot Short Circuit (High) TM L03
system
Electrical
DXH3KA ECMV Solenoid Open Circuit (Low) TM L03
system
Electrical
DXH3KB ECMV Solenoid Ground Fault (Low) TM L03
system
Electrical
DXH3KY ECMV Solenoid Hot Short Circuit (Low) TM L03
system
Electrical
DXH4KA ECMV Solenoid Open Circuit (1st) TM L03
system
Electrical
DXH4KB ECMV Solenoid Ground Fault (1st) TM L03
system
Electrical
DXH4KY ECMV Solenoid Hot Short Circuit (1st) TM L03
system
Electrical
DXH5KA ECMV Solenoid Open Circuit (2nd) TM L03
system
Electrical
DXH5KB ECMV Solenoid Ground Fault (2nd) TM L03
system
Electrical
DXH5KY ECMV Solenoid Hot Short Circuit (2nd) TM L03
system
Electrical
DXH6KA ECMV Solenoid Open Circuit (3rd) TM L03
system
Electrical
DXH6KB ECMV Solenoid Ground Fault (3rd) TM L03
system
Electrical
DXH6KY ECMV Solenoid Hot Short Circuit (3rd) TM L03
system
Electrical
DXH7KA ECMV Solenoid Open Circuit (Reverse) TM L03
system
Electrical
DXH7KB ECMV Solenoid Ground Fault (Reverse) TM L03
system
Electrical
DXH7KY ECMV Solenoid Hot Short Circuit (Reverse) TM L03
system
Electrical
DXHHKA Clutch Solenoid Output Open Circuit (4th) TM L03
system
40-190 HD465-8, HD605-8


component gory
Electrical
DXHHKB Clutch Solenoid Output Ground Fault (4th) TM L03
system
Electrical
DXHHKY Clutch Solenoid Output Hot Short Circuit (4th) TM L03
system
Electrical
DY30MA Secondary Steering Release Trouble RHC L01
system
Electrical
DY30MC Secondary Steering Activity Malfunction RHC L03
system
Mechanical
DY30ME Secondary Steering Long Time Activated RHC L02
system
Mechanical
F@BYNR Exhaust Temperature Abnormal Rising 2 KOMTRAX -
system
Mechanical
F@BYNS Exhaust Temperature Abnormal Rising 1 KOMTRAX -
system
q In this table, failure codes are arranged in the sequence of the alphabet.
q Applicable component is the controller which check the system.
MON: Machine monitor
ENG: Engine controller
T/M: Transmission controller
RHC: Retarder and hoist controller
KOMTRAX: KOMTRAX Plus controller
ABS: ABS controller
q The failure codes that do not have numbers in the action level cells are not shown on the standard screen. Although a failure
related to them occurs. They are simply recorded in the Abnormality Record (electrical system or mechanical system) of
the Service Solutions.
q The past category is the recorded electrical system or mechanical system which is used to keep the Abnormality Record
of Service Solutions.
HD465-8, HD605-8 40-191

FAILURE CODE [1500L0] 40 TROUBLESHOOTING
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF

CODE)
FAILURE CODE [1500L0]
Action level Failure code T/M Clutches Double Engagement
Failure
L04 1500L0 (Transmission controller system)
Details of fail- Either the clutch ECMV or the fill switch is defective. Fill switch signals from the combination of 2 or more
ure clutches are input.
q Shifts gear speed to NEUTRAL and holds it.
Action of con-
q Although the cause of failure is eliminated, the machine does not resume normal operation until the start
troller
switch is turned to the OFF position.
Effect to the q Gear speed is held in NEUTRAL and gear shift is not functional.
machine q When the emergency brake is applied, transmission damage is possible.
Related infor- After the repair is completed, make sure the failure code is removed. Use the procedure which follows.
mation Procedure: Start the engine and operate the machine.
No. Cause Procedures, test locations, specifications and remarks

Generation of a failure
code (15S*L1 or DXH*KY)
1 Troubleshoot for a generated failure code.
related to clutch pressure
control valve system
Defective hydraulic or
2 mechanical system of Clutch ECMV may be defective. Troubleshoot hydraulic and mechanical systems.
clutch ECMV
Defective transmission If there is no failure with the checks above, the transmission controller is defective. (Since
3
controller this is an internal problem, you cannot troubleshoot.)
40-192 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [15B0NX]
FAILURE CODE [15B0NX]

Action level Failure code T/M Oil Filter Clogging
Failure
L01 15B0NX (Transmission controller system)
Details of fail- The torque converter oil temperature rises above 50 °C. Therefore, signal circuit of the transmission blockage
ure sensor 1 or the transmission blockage sensor 2 is open (disconnected from GND).
Action of con-
None in particular
troller
Effect to the
If the machine is used without repairing, dust may enter the transmission circuit.
machine
q After repairing the failure and confirming resetting of the machine, perform the initial learning of the trans-
Related infor- mission controller, referring to TEST AND ADJUST, "SET AND OPERATE OF MACHINE MONITOR".
mation q After the repair is completed, make sure the failure code is removed. Use the procedure which follows.
Procedure: Start the engine.

Clogged transmission oil
1 Make sure the transmission oil filter is not clogged. If it is clogged, clean or replace it.
filter
1. Turn the start switch to the OFF position.

2. Disconnect connector TMF1, and connect T-adapter to the male side.
Defective transmission oil
2
filter blockage sensor 1 Between TMF1 (male) (1) When filter is normal Max. 1 Ω
Resistance
and (2) When the filter is clogged Min. 1 MΩ

2. Disconnect connector TMF2, and connect T-adapter to the male side.
Defective transmission oil 3. Turn the start switch to the ON position
3
filter blockage sensor 2
Between TMF2 (male) (1) When filter is normal Max. 1 Ω
Resistance

2. Disconnect connectors ATC2, ATC3, TMF1, and TMF2, and connect T-adapter to
each female side.
Open circuit in wiring har- Between ATC2 (female) (7) and TMF1 (female) (1) Max. 1 Ω
4
ness
Between ATC2 (female) (13) and TMF2 (female) (1) Max. 1 Ω
Resistance
Between TMF1 (female) (2) and ATC3 (female) (21) Max. 1 Ω
Between TMF2 (female) (2) and ATC3 (female) (21) Max. 1 Ω

2. Put T-adapter into connector ATC2 and ATC3.
3. Turn the start switch to the ON position
Between ATC2 (7) and When filter is normal Max. 1 V

Defective transmission ATC3 (21) When the filter is clogged 6 to 12 V
5
controller Voltage
Between ATC2 (13) and When the filter is normal Max. 1 V
ATC3 (21) When the filter is clogged 6 to 12 V
If there is no failure with the checks above, the transmission controller is defective. (Since
this is an internal problem, you cannot troubleshoot.)
HD465-8, HD605-8 40-193

FAILURE CODE [15B0NX] 40 TROUBLESHOOTING
Circuit diagram related to transmission oil filter
40-194 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [15F0KM]
FAILURE CODE [15F0KM]

Action level Failure code Gear Shifting from R to F Abuse 1
Failure
- 15F0KM (Transmission controller system)
Details of fail- A total of 10 reverse-to-forward shifts are sensed at output shaft speed of 200 to 300 rpm (approximately 4 to
ure 6 km/h).
Action of con-
None in particular
troller
Effect to the q If the operations described in details of failure are done again, machine damage is possible.
machine q Only recorded in Defect Record.
Related infor-
mation

q Always stop the machine completely and release the accelerator pedal before you
perform the direction selection. (Instruct the operator on correct operation of ma-
Defective operation of the chine.)
1
gear shift lever q Apply force in addition to the force of operation of the gear shift lever, and it depresses
the lever.
q Gear shift lever is stopped at the middle point between 2 positions.
2
HD465-8, HD605-8 40-195

FAILURE CODE [15F0MB] 40 TROUBLESHOOTING
FAILURE CODE [15F0MB]

Action level Failure code Gear Shifting from R to F Abuse 2
Failure
- 15F0MB (Transmission controller system)
Details of fail-
A total of 5 reverse-to-forward shifts are sensed at output shaft speed of 300 rpm (approximately 7 km/h).
ure
Action of con-
None in particular
troller
Related infor-
mation

1
the lever.
2
40-196 HD465-8, HD605-8


Action level Failure code T/M Clutch Disk Abuse (Forward)
Failure
Details of fail- Total of 10 directional changes from NEUTRAL or REVERSE to FORWARD are detected while engine speed
ure is 1800 rpm or higher.
Action of con-
None in particular
troller
Related infor-
mation

1
the lever.
2
HD465-8, HD605-8 40-197

FAILURE CODE [15G0MW] 40 TROUBLESHOOTING
FAILURE CODE [15G0MW]

Action level Failure code T/M Clutch Slipping (Reverse)
Failure (R instruction, R clutch fill switch ON, slip sensed)
L03 15G0MW (Transmission controller system)
Details of fail- The controller operates R clutch ECMV. A problem is found in the value calculated with the transmission input
ure shaft, transmission middle shaft, and transmission output shaft speed sensors.
q Shifts gear speed to NEUTRAL, refers to gear speed when a failure is sensed as shown in Table 1, and
Action of con-
holds it.
troller
q Disengages lockup clutch.
machine q Machine cannot move off once gear shift lever is set to "N" position.
k Before you perform this procedure, raise the body to the maximum height. Be sure to set the hoist
lever to "HOLD". Set the lock knob to LOCK, and put in the body pivot pin.
Related infor- q If failure code [DLT3LC] is also shown, troubleshoot for it first.
mation q When you operate the limp-home function, see Operation and Maintenance Manual, "How to troubleshoot
failures of the transmission".
q After the repair is completed, make sure the failure code is removed. Use the procedure which follows.
Procedure: Start the engine and operate the machine rearward.
Defective hydraulic or 1. Examine for failures such as a blocked transmission oil filter.
1 mechanical system of R 2. Make sure that clutch pressure is normal, refer to TEST AND ADJUST, "TEST
clutch POWER TRAIN OIL PRESSURE".
2
Table 1
Solution when a failure is sensed

Gear speed when a failure
Unusual clutch Action of controller ON/OFF condition
is sensed
(Selected clutch, gear speed) of lockup clutch
4th 4th OFF NEUTRAL OFF

F7
High High OFF NEUTRAL OFF

F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF

F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF

F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF

F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF

F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF

F1
Low Low 2H F3 OFF
R Reverse Reverse OFF NEUTRAL OFF

(RL) Low Low RH R OFF
40-198 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [15G7KM]
FAILURE CODE [15G7KM]

Action level Failure code T/M Clutch Disk Abuse (Reverse)
Failure
- 15G7KM (Transmission controller system)
Details of fail- Total of 10 direction changes from NEUTRAL or FORWARD to REVERSE are sensed while engine speed is
ure 1800 rpm or higher.
Action of con-
None in particular
troller
Related infor-
mation

1
the lever.
2
HD465-8, HD605-8 40-199

FAILURE CODE [15H0MW] 40 TROUBLESHOOTING
FAILURE CODE [15H0MW]

Action level Failure code T/M Clutch Slipping (High)
Failure (H instruction, H clutch fill switch ON, slip sensed)
L03 15H0MW (Transmission controller system)
Details of fail- The controller operates H clutch ECMV. A problem is found in the value calculated with the transmission input
ure shaft, transmission middle shaft, and transmission output shaft speed sensors.
q Shifts up the gear (it refers to gear speed) when a failure is sensed as shown in Table 1 and holds that
Action of con-
gear speed.
troller
q Machine travels in gear speed that does not use H clutch.
Effect to the
q The gear shift lever is set to "N" during travel. Although the gear shift lever is moved to a position other
machine
than "N", a gear shift is not performed until the machine is stopped.
Related infor- q When you operate the limp-home function, see Operation and Maintenance Manual, "How to troubleshoot
mation failures of the transmission".
Procedure: Start the engine and operate the machine in F3.
1 mechanical system of H 2. Make sure that clutch pressure is normal, refer to TEST AND ADJUST, "TEST
2
Table 1

is sensed

F7

F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF

F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF

F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF

F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF

F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF

F1
Low Low 2H F3 OFF

40-200 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [15J0MW]
FAILURE CODE [15J0MW]

Action level Failure code T/M Clutch Slipping (Low)
Failure (L instruction, L clutch fill switch ON, slip sensed)
L03 15J0MW (Transmission controller system)
Details of fail- The controller operates L clutch ECMV. A problem is found with the value calculated with the transmission
ure input shaft, transmission middle shaft, and transmission output shaft speed sensors.
q Shifts up the gear (it refers to gear speed) speed when a failure is sensed as shown in Table 1 and holds
Action of con-
that gear speed.
troller
q Machine travels in gear speed that does not use L clutch.
Effect to the
machine
Related infor- q When you operate the limp-home function, see Operation and Maintenance Manual, "How to troubleshoot
mation failures of the transmission".
1 mechanical system of L 2. Make sure that clutch pressure is normal, refer to TEST AND ADJUST, "TEST
2
Table 1

is sensed

F7

F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF

F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF

F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF

F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF

F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF

F1
Low Low 2H F3 OFF

HD465-8, HD605-8 40-201

FAILURE CODE [15K0MW] 40 TROUBLESHOOTING
FAILURE CODE [15K0MW]

Action level Failure code T/M Clutch Slipping (1st)
Failure (1st instruction, 1st clutch fill switch ON, slip sensed)
L03 15K0MW (Transmission controller system)
Details of fail- The controller operates 1st clutch ECMV. A problem is found in the value calculated with the transmission
q Shifts up the gear and refer to gear speed when a failure is sensed as shown in Table 1 and holds that
Action of con-
gear speed.
troller
q Machine travels in gear speed (F2) that does not use 1st clutch.
Effect to the q The gear shift lever is set to "N" during travel. Although the gear shift lever is moved to a position other
machine than "N", a gear shift is not performed until the machine is stopped.
q Machine cannot move off once gear shift lever is set to the "N" position.
1 mechanical system of 1st 2. Make sure that clutch pressure is normal, refer to TEST AND ADJUST, "TEST
2
Table 1

is sensed

F7

F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF

F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF

F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF

F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF

F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF

F1
Low Low 2H F3 OFF
40-202 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [15K0MW]

is sensed

HD465-8, HD605-8 40-203

FAILURE CODE [15L0MW] 40 TROUBLESHOOTING
FAILURE CODE [15L0MW]

Action level Failure code T/M Clutch Slipping (2nd)
Failure (2nd instruction, 2nd clutch fill switch ON, slip sensed)
L03 15L0MW (Transmission controller system)
Details of fail- The controller operates 2nd clutch ECMV. A problem is found in the value calculated with the transmission
Action of con-
gear speed.
troller
q Machine travels in gear speed (F4) that does not use the 2nd clutch.
Procedure: Start the engine and move the machine in F2.
1 mechanical system of the 2. Make sure that clutch pressure is normal, refer to TEST AND ADJUST, "TEST
2nd clutch POWER TRAIN OIL PRESSURE".
2
Table 1

is sensed

F7

F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF

F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF

F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF

F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF

F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF

F1
Low Low 2H F3 OFF
40-204 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [15L0MW]

is sensed

HD465-8, HD605-8 40-205

FAILURE CODE [15M0MW] 40 TROUBLESHOOTING
FAILURE CODE [15M0MW]

Action level Failure code T/M Clutch Slipping (3rd)
Failure (3rd instruction, 3rd clutch fill switch ON, slip sensed)
L03 15M0MW (Transmission controller system)
Details of fail- The controller operates 3rd clutch ECMV. A problem is found in the value calculated with the transmission
q Shifts up the gear and refer to gear speed when a failure is sensed as shown in Table 1 and holds that
Action of con-
gear speed.
troller
q Machine travels in gear speed (F6) that does not use the 3rd clutch.
3rd clutch POWER TRAIN OIL PRESSURE".
2
Table 1

is sensed

F7

F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF

F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF

F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF

F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF

F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF

F1
Low Low 2H F3 OFF
40-206 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [15M0MW]

is sensed

HD465-8, HD605-8 40-207

FAILURE CODE [15N0MW] 40 TROUBLESHOOTING
FAILURE CODE [15N0MW]

Action level Failure code Clutch System Abnormality (4th)
Failure (4th instruction, 4th clutch fill switch ON, slip sensed)
L03 15N0MW (Transmission controller system)
Details of fail- When you run 4th clutch ECMV. A problem is found in the values calculated with the transmission input shaft,
ure transmission middle shaft, and transmission output shaft speed sensors.
Action of con-
holds it.
troller
machine q Machine cannot move off once gear shift lever is set to the "N" position.
q If failure code [DLT3LC] is also shown, troubleshoot for it first.
Related infor- q Examine for mechanical failures such as a problem in the 4th clutch, or a clogged oil filter of the pressure
mation control valve.
q When you operate the limp-home function, see Operation and Maintenance Manual, "How to troubleshoot
4th clutch POWER TRAIN OIL PRESSURE".
2
Table 1

is sensed

F7

F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF

F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF

F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF

F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF

F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF

F1
Low Low 2H F3 OFF
40-208 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [15N0MW]

is sensed
Reverse Reverse OFF NEUTRAL OFF

R (RL)
Low Low RH R OFF
HD465-8, HD605-8 40-209

FAILURE CODE [15SBL1] 40 TROUBLESHOOTING
FAILURE CODE [15SBL1]

Action level Failure code ECMV Release Trouble (Reverse Clutch)
Failure
L03 15SBL1 (Transmission controller system)
Details of fail-
Signal from the fill switch remains "ON" after controller stops to operate R clutch ECMV.
ure
q Shifts gear speed to NEUTRAL and refers to gear speed when a failure is sensed as shown in Table 2
Action of con-
and holds it.
troller
q Gear speed is held in NEUTRAL and a gear shift is not possible until the machine is stopped.
Effect to the
q The machine stops, it can move rearward by setting the gear shift lever to R. The machine cannot move
machine
forward by setting the gear shift lever to a position between D and L.
Related infor- q Examine for mechanical failures such as a problem in R clutch, or a clogged oil filter of pressure control
mation valve.

Defective R clutch ECMV 2. Disconnect connector R, SW, and connect T-adapter to the male side.
1
fill switch
Resistance Between R,SW (male) (1) and ground Min. 1 MΩ

Ground fault in wiring har- 2. Disconnect connectors ATC3 and R, SW, and connect T-adapter to either female side.
2
ness Between ground and ATC3 (female) (29) or R,SW (female)
Resistance Min. 1 MΩ
(1)

Short circuit in wiring har- 2. Disconnect connector ATC3, and connect T-adapter to the female side.
3
ness Between ATC3 (female) (29) and each pin other than pin
Continuity No continuity
(29)
1. Check that transmission R clutch operation pressure is normal, referring to TEST AND
ADJUST, "TEST POWER TRAIN OIL PRESSURE".
2. Operate the gear shift lever to "L" position with the testing tools installed as they are.
If the clutch oil pressure exceeds the following standard value, the R clutch ECMV is
4 Defective R clutch ECMV defective.
Max. 0.2
Oil pressure R clutch Gear shift lever: "L" MPa {2
kg/cm2}

2. Insert T-adapter into connector ATC3.
Defective transmission
5
controller Voltage Between ATC3 (29) and ground 6 to 12 V
40-210 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [15SBL1]
Circuit diagram related to R clutch
Table 2

is sensed
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
F7 1st OFF NEUTRAL OFF
High
Reverse OFF NEUTRAL OFF
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
HD465-8, HD605-8 40-211

FAILURE CODE [15SBL1] 40 TROUBLESHOOTING

is sensed
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
R 2nd OFF NEUTRAL OFF
Low
1st OFF NEUTRAL OFF
High RH R OFF
N - ANY NONE Non remedy -
40-212 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [15SBMA]
FAILURE CODE [15SBMA]

Action level Failure code ECMV Engage Trouble (Reverse Clutch)
Failure (R instruction, R clutch fill switch OFF, slip sensed)
L03 15SBMA (Transmission controller system)
The controller runs clutch ECMV with the signal from the fill switch at "OFF". A problem is found in the value
Details of fail-
calculated with the transmission input shaft, the transmission middle shaft, and transmission output shaft
ure
speed sensors.
Action of con-
holds it. (See failure code [15G0MW].)
troller
Effect to the
q The machine stops. It can move forward when the gear speed is set to F2 by setting the gear shift lever
machine
to a position between D and L. But, the machine cannot move rearward by setting the gear shift lever to R.
mation q Examine for mechanical failures such as a problem in R clutch, or a clogged oil filter of the pressure con-
trol valve.
Procedure: Start the engine and move the machine in R1.

Defective R clutch ECMV
1 Perform troubleshooting for failure code [15G0MW].
system
Table 1

is sensed

F7

F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF

F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF

F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF

F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF

F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF

F1
Low Low 2H F3 OFF

HD465-8, HD605-8 40-213

FAILURE CODE [15SCL1] 40 TROUBLESHOOTING
FAILURE CODE [15SCL1]

Action level Failure code ECMV Release Trouble (High Clutch)
Failure
L03 15SCL1 (Transmission controller system)
Details of fail-
Signal from the fill switch remains "ON" after controller stops to operate H clutch ECMV.
ure
Action of con-
gear speed.
troller
q Machine travels in gear speed that uses H clutch.
Effect to the than "N", a gear shift is not performed until the machine is stopped.
machine q The machine can move forward when the gear speed is set to F2 by setting the gear shift lever to a posi-
tion between D and L. The machine can move rearward when the gear speed is set to R by setting the
gear shift lever to R.
Related infor- q Examine for mechanical failures such as a problem in H clutch or a clogged oil filter of the pressure control
mation valve.

Defective H clutch ECMV 2. Disconnect connector H, SW, and connect T-adapter to the male side.
1
fill switch
Resistance Between H, SW (male) (1) and ground Min. 1 MΩ

Ground fault in wiring har- 2. Disconnect connectors ATC2 and H, SW, and connect T-adapter to either female side.
2
ness Between ground and ATC2 (female) (27) or H,SW (female)
(1)

3
(27)
1. Check that transmission H clutch operation pressure is normal, referring to TEST AND
ADJUST, "TEST POWER TRAIN OIL PRESSURE".
If the clutch oil pressure exceeds the following standard value, the H clutch ECMV is
4 Defective H clutch ECMV defective.
Max. 0.2
Oil pressure H clutch Gear shift lever: "L" MPa {2
kg/cm2}

5
40-214 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [15SCL1]
Circuit diagram related to H clutch
Table 2

is sensed
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
HD465-8, HD605-8 40-215

FAILURE CODE [15SCL1] 40 TROUBLESHOOTING

is sensed
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH R OFF
40-216 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [15SCMA]
FAILURE CODE [15SCMA]

Action level Failure code ECMV Engage Trouble (High Clutch)
Failure (H instruction, H clutch fill switch OFF, slip sensed)
L03 15SCMA (Transmission controller system)
The controller operates H clutch ECMV with the signal from the fill switch at "OFF". A problem is found in the
Details of fail-
value calculated with the transmission input shaft, transmission middle shaft, and transmission output shaft
ure
speed sensors.
q Shifts up the gear (it refers to gear speed) before failure as shown in Table 1 and holds that gear speed.
Action of con-
(See failure code [15H0MW].)
troller
q Machine travels in gear speed that does not use H clutch.
machine q The machine stops. It can move forward when the gear speed is set to F2 and you set the gear shift lever
to a position between D and L. The machine can move rearward when the gear speed is set to R and you
set the gear shift lever to R position.
Related infor- q Examine for mechanical failures such as a problem in H clutch or a clogged oil filter of the pressure control
mation valve.

Defective H clutch ECMV
1 Troubleshoot for failure code [15H0MW].
system
Table 1

is sensed

F7

F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF

F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF

F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF

F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF

F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF

F1
Low Low 2H F3 OFF

HD465-8, HD605-8 40-217

FAILURE CODE [15SDL1] 40 TROUBLESHOOTING
FAILURE CODE [15SDL1]

Action level Failure code ECMV Release Trouble (Low Clutch)
Failure
L03 15SDL1 (Transmission controller system)
Details of fail- Signal from the fill switch remains "ON" and the clutch is not released, after the controller stops to operate L
ure clutch ECMV.
Action of con-
gear speed.
troller
q Machine travels in gear speed that uses L clutch.
Related infor- q Examine for mechanical failures such as a problem in L clutch, or a clogged oil filter of the pressure control
mation valve.
No. Cause Procedures location of measure, specification and notes

Defective L clutch ECMV 2. Disconnect connector L, SW, and connect T-adapter to the male side.
1
fill switch
Resistance Between L, SW (male) (1) and ground Min. 1 MΩ

Ground fault in wiring har- 2. Disconnect connectors ATC2 and L, SW, and connect T-adapter to either female side.
2
ness Between ground and ATC2 (female) (37) or L,SW (female)
(1)

3
(37)
1. Check that the operation pressure of transmission L clutch is normal, referring to

TEST AND ADJUST, "TEST POWER TRAIN OIL PRESSURE".
2. Operate the gear shift lever to "N" position with the testing tools installed as they are.
If the clutch oil pressure exceeds the following standard value, the L clutch ECMV is
4 Defective L clutch ECMV defective.
Max. 0.2
Oil pressure L clutch Gear shift lever: "N" MPa {2
kg/cm2}

5
40-218 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [15SDL1]
Circuit diagram related to L clutch
Table 2

is sensed
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
HD465-8, HD605-8 40-219

FAILURE CODE [15SDL1] 40 TROUBLESHOOTING

is sensed
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH R OFF
40-220 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [15SDMA]
FAILURE CODE [15SDMA]

Action level Failure code ECMV Engage Trouble (Low Clutch)
Failure (L instruction, L clutch fill switch OFF, slip sensed)
L03 15SDMA (Transmission controller system)
The controller operates H clutch ECMV with the signal from the fill switch being "OFF". A problem is found in
Details of fail-
the value calculated with the transmission input shaft, transmission middle shaft, and transmission output
ure
shaft speed sensors.
Action of con-
(See failure code [15J0MW].)
troller
q Machine travels in gear speed that does not use L clutch.
Related infor- q Examine for mechanical failures such as a problem in L clutch, or a clogged oil filter of the pressure control
mation valve.

Defective L clutch ECMV
1 Troubleshoot for failure code [15J0MW].
system
Table 1

is sensed

F7

F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF

F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF

F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF

F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF

F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF

F1
Low Low 2H F3 OFF

HD465-8, HD605-8 40-221

FAILURE CODE [15SEL1] 40 TROUBLESHOOTING
FAILURE CODE [15SEL1]

Action level Failure code ECMV Release Trouble (1st Clutch)
Failure
L03 15SEL1 (Transmission controller system)
Details of fail-
Signal from the fill switch remains "ON" after controller stops operation of 1st clutch ECMV.
ure
q Shifts gear speed to NEUTRAL (it refers to gear speed) when failure is detected as shown in Table 2 and
Action of con-
holds it.
troller
Effect to the q The machine stops. It can move forward when the gear speed is set to F1 and you set the gear shift lever
machine to a position between D and L. But, the machine cannot move rearward when you set the gear shift lever
to R.
Related infor- q Examine for mechanical failures such as a problem in 1st clutch, or a clogged oil filter of the pressure con-
mation trol valve.
No. Cause Procedure, test locations, specifications and remarks

Defective 1st clutch ECMV 2. Disconnect connector 1, SW, and connect T-adapter to the male side.
1
fill switch
Resistance Between 1,SW (male) (1) and ground Min. 1 MΩ

Ground fault in wiring har- 2. Disconnect connectors ATC2 and 1, SW, and connect T-adapter to either female side.
2
ness Between ground and ATC2 (female) (12) or 1,SW (female)
(1)

3
(12)
1. Check that transmission 1st clutch operation pressure is normal, referring to TEST
AND ADJUST, "TEST POWER TRAIN OIL PRESSURE".
2. Operate the gear shift lever to "D" position with the testing tools installed as they are.
If the clutch oil pressure exceeds the following standard value, the 1st clutch ECMV is
4 Defective 1st clutch ECMV defective.
Max. 0.2
Oil pressure 1st clutch Gear shift lever: "D" MPa {2
kg/cm2}

5
40-222 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [15SEL1]
Circuit diagram related to 1st clutch
Table 2

is sensed
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
HD465-8, HD605-8 40-223

FAILURE CODE [15SEL1] 40 TROUBLESHOOTING

is sensed
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH R OFF
40-224 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [15SEMA]
FAILURE CODE [15SEMA]

Action level Failure code ECMV Engage Trouble (1st Clutch)
Failure (1st instruction, 1st clutch fill switch OFF, slip sensed)
L03 15SEMA (Transmission controller system)
The controller operates 1st clutch ECMV with the signal from the fill switch at "OFF". A problem is found in the
Details of fail-
ure
speed sensors.
Action of con-
(See failure code [15K0MW].)
troller
q Machine travels in gear speed that does not use 1st clutch.
mation q Examine for mechanical failures such as a problem in 1st clutch, or a clogged oil filter of the pressure con-
trol valve.

Defective 1st clutch ECMV
1 Troubleshoot for failure code [15K0MW].
system
Table 1

is sensed

F7

F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF

F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF

F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF

F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF

F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF

F1
Low Low 2H F3 OFF

HD465-8, HD605-8 40-225

FAILURE CODE [15SFL1] 40 TROUBLESHOOTING
FAILURE CODE [15SFL1]

Action level Failure code ECMV Release Trouble (2nd Clutch)
Failure
L03 15SFL1 (Transmission controller system)
Details of fail-
Signal from the fill switch remains "ON" after controller stops to operate 2nd clutch ECMV.
ure
q Shifts up the gear with gear speed when a failure is sensed as shown in Table 2 and holds that gear
Action of con-
speed.
troller
q Machine travels in gear speed that uses the 2nd clutch.
Effect to the
machine
q The machine stops. It can move forward when the gear speed is set to F2 by setting the gear shift lever
to a position between D and L. But, the machine cannot move rearward by setting the gear shift lever to R.
Related infor- q Examine for mechanical failures such as a problem in the 2nd clutch, or a clogged oil filter of the pressure

Defective 2nd clutch 2. Disconnect connector 2, SW, and connect T-adapter to the male side.
1
ECMV fill switch
Resistance Between 2,SW (male) (1) and ground Min. 1 MΩ

2
(1)

3
ness
Continuity Between ATC2 (female) (2) and each pin other than pin (2) No continuity
1. Check that transmission 2nd clutch operation pressure is normal, referring to TEST
Defective 2nd clutch If the clutch oil pressure exceeds the following standard value, the 2nd clutch ECMV
4 is defective.
ECMV
Max. 0.2
Oil pressure 2nd clutch Gear shift lever: "L" MPa {2
kg/cm2}

5
40-226 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [15SFL1]
Circuit diagram related to 2nd clutch
Table 2

is sensed
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
HD465-8, HD605-8 40-227

FAILURE CODE [15SFL1] 40 TROUBLESHOOTING

is sensed
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH R OFF
40-228 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [15SFMA]
FAILURE CODE [15SFMA]

Action level Failure code ECMV Engage Trouble (2nd Clutch)
Failure (2nd instruction, 2nd clutch fill switch OFF, slip sensed)
L03 15SFMA (Transmission controller system)
The controller operates 2nd clutch ECMV with the signal from the fill switch at "OFF". A problem is found in
Details of fail-
the value calculated with the transmission input shaft, transmission middle shaft, and transmission output
ure
shaft speed sensors.
Action of con-
(See failure code [15L0MW].)
troller
q Machine travels in gear speed (F4) that does not use the 2nd clutch.
machine q The machine stops. It can move forward when the gear speed is set to F1and you set the gear shift lever
to a position between D and L. The machine can move rearward when the gear speed is set to R by setting
the gear shift lever to R.
mation q Examine for mechanical failures such as a problem in the 2nd clutch, or a clogged oil filter of the pressure
control valve.

Defective 2nd clutch
1 Troubleshoot for failure code [15L0MW].
ECMV system
Table 1

is sensed

F7

F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF

F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF

F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF

F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF

F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF

F1
Low Low 2H F3 OFF

HD465-8, HD605-8 40-229

FAILURE CODE [15SGL1] 40 TROUBLESHOOTING
FAILURE CODE [15SGL1]

Action level Failure code ECMV Release Trouble (3rd Clutch)
Failure
L03 15SGL1 (Transmission controller system)
Details of fail-
Signal from the fill switch remains "ON" after controller stops to operate 3rd clutch ECMV.
ure
q Shifts up the gear with gear speed when a failure is sensed as shown in Table 2 and holds that gear
Action of con-
speed.
troller
q Machine travels in gear speed that uses the 3rd clutch.
to a position between D and L. But the machine cannot move rearward when you set the gear shift lever
to R.
Related infor- q Examine for mechanical failures such as a problem in the 3rd clutch, or a clogged oil filter of the pressure

Defective 3rd clutch ECMV 2. Disconnect connector 3, SW, and connect T-adapter to the male side.
1
fill switch
Resistance Between 3, SW (male) (1) and ground Min. 1 MΩ

2
(1)

3
(36)
1. Check that transmission 3rd clutch operation pressure is normal, referring to TEST
If the clutch oil pressure exceeds the following standard value, the 3rd clutch ECMV
4 Defective 3rd clutch ECMV is defective.
Max. 0.2
Oil pressure 3rd clutch Gear shift lever: "L" MPa {2
kg/cm2}

5
40-230 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [15SGL1]
Circuit diagram related to 3rd clutch
Table 2

is sensed
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
HD465-8, HD605-8 40-231

FAILURE CODE [15SGL1] 40 TROUBLESHOOTING

is sensed
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH R OFF
40-232 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [15SGMA]
FAILURE CODE [15SGMA]

Action level Failure code ECMV Engage Trouble (3rd Clutch)
Failure (3rd instruction, 3rd clutch fill switch OFF, slip sensed)
L03 15SGMA (Transmission controller system)
The controller operates 3rd clutch ECMV with the signal from the fill switch at "OFF". A problem is found in the
Details of fail-
ure
speed sensors.
Action of con-
(See failure code [15M0MW].)
troller
q Machine travels in gear speed (F6) that does not use the 3rd clutch.
mation q Examine for mechanical failures such as a problem in the 3rd clutch, or a clogged oil filter of the pressure
control valve.

Defective 3rd clutch ECMV
1 Troubleshoot for failure code [15M0MW].
system
Table 1

is sensed

F7

F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF

F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF

F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF

F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF

F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF

F1
Low Low 2H F3 OFF

HD465-8, HD605-8 40-233

FAILURE CODE [15SHL1] 40 TROUBLESHOOTING
FAILURE CODE [15SHL1]

Action level Failure code ECMV Release Trouble (4th Clutch)
Failure
L03 15SHL1 (Transmission controller system)
Details of fail-
Signal from the fill switch remains "ON" after controller stops to operate 4th clutch ECMV.
ure
Action of con-
gear speed.
troller
q If the gear shift lever is set to the "N" position as you travel, a gear shift is not possible until the machine
Effect to the is stopped. The machine shifts up the gear and moves in F6.
machine q The machine stops. The gear speed is set to F6 as you set the gear shift lever to a position between D
and L. But, the machine cannot move rearward.
Related infor- q Examine for mechanical failures such as a problem in the 4th clutch, or a clogged oil filter of the pressure
Procedure: Start the engine and move the machine in F1 or F2.

Defective 4th clutch ECMV 2. Disconnect connector 4, PS, and connect T-adapter to the male side.
1
fill switch
Resistance Between 4, PS (male) (1) and ground Min. 1 MΩ

Ground fault in wiring har- 2. Disconnect connectors ATC2 and 4, PS, and connect T-adapter to either female side.
2
ness Between ground and ATC2 (female) (38) or 4,PS (female)
(1)

3
(38)
1. Check that transmission 4th clutch operation pressure is normal, referring to TEST
If the clutch oil pressure exceeds the following standard value, the 4th clutch ECMV is
4 Defective 4th clutch ECMV defective.
Max. 0.2
Oil pressure 4th clutch Gear shift lever: "L" MPa {2
kg/cm2}

2. Insert T-adapter to connector ATC2.
5
40-234 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [15SHL1]
Circuit diagram related to 4th clutch
Table 2

is sensed
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
HD465-8, HD605-8 40-235

FAILURE CODE [15SHL1] 40 TROUBLESHOOTING

is sensed
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH R OFF
40-236 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [15SHMA]
FAILURE CODE [15SHMA]

Action level Failure code ECMV Malfunction (4th Clutch)
Failure (4th instruction, 4th clutch fill switch OFF, slip sensed)
L03 15SHMA (Transmission controller system)
The controller operates 4th clutch ECMV with the signal from the fill switch at "OFF". A problem is found in the
Details of fail-
ure
speed sensors.
q Shifts gear speed to NEUTRAL (it refers to gear speed) when a failure is sensed as shown in Table 1,
Action of con-
and holds it. (See failure code [15N0MW].)
troller
machine q Machine cannot move off once gear shift lever is set to the "N" position.
mation q Examine for mechanical failures such as a problem in the 4th clutch, or a clogged oil filter of the pressure
control valve.

Defective 4th clutch ECMV
1 Troubleshoot for failure code [15N0MW].
system
Table 1

is sensed

F7

F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF

F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF

F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF

F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF

F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF

F1
Low Low 2H F3 OFF
Reverse Reverse OFF NEUTRAL OFF

R (RL)
Low Low RH R OFF
HD465-8, HD605-8 40-237

FAILURE CODE [15SJMA] 40 TROUBLESHOOTING
FAILURE CODE [15SJMA]

Action level Failure code ECMV Engage Trouble (Lock Up Clutch)
Failure (Lockup instruction, slip sensed)
L03 15SJMA (Transmission controller system)
Details of fail- The controller operates lockup clutch ECMV. A problem is found in the value calculated with the engine, the
ure transmission input shaft, transmission middle shaft, and the transmission output shaft speed sensors.
Action of con- q Keeps present gear speed and disengages the lockup clutch.
troller q Transmission will stay in neutral when the gear shift lever is set to the "N" position.
q Lockup clutch is disengaged and it becomes impossible to shift gears.
Related infor- q If failure code [CA115], [CA689], [CA731], or [CA778] is also displayed, troubleshoot for it first.
mation q Examine for mechanical failures such as a problem in the lockup clutch, or a clogged oil filter of pressure
control valve.
Procedure: Start the engine, move the machine in F1, and turn on the lockup pilot lamp.
lockup clutch POWER TRAIN OIL PRESSURE".
2
40-238 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [2C4MNX]
FAILURE CODE [2C4MNX]

Action level Failure code Brake Cooling Oil Filter Clogging
Failure
L01 2C4MNX (Machine monitor system)
Details of fail- The retarder oil temperature is above 50 °C while the engine operates. The signal circuit of the retarder cooler
ure oil filter switch is opened (disconnected from GND).
Action of con-
None in particular
troller
Effect to the
If the machine is used as it is, damage to the retarder brake is possible.
machine
q The monitor examines the retarder cooler oil filter switch input signal.
Related infor- (Code: 04510) (Normal: OFF, blockage: ON)

Clogged retarder cooler fil-
1 Make sure the retarder cooler filter is not clogged. If it is clogged, clean or replace it.
ter

2. Disconnect connector BCF, and connect T-adapter to the male side.
Defective retarder cooler 3. Turn the start switch to the ON position
2
filter switch
Between BCF (male) (1) and When filter is normal Max. 1 Ω
Resistance
(2) When the filter is clogged Min. 1 MΩ

2. Disconnect connector MCM1 and BCF, and connect T-adapter to each female side.
Open circuit in wiring har-
3
ness Between MCM1 (female) (50) and BCF (female) (1) Max. 1 Ω
Resistance
Between MCM1 (female) (13) and BCF (female) (2) Max. 1 Ω

2. Put T-adapter into connector MCM1.
Defective monitor control- When filter is normal Max. 1 V
4 Between MCM1 (50) and
ler Voltage
(13) When the filter is clogged 6 to 12 V
Circuit diagram related to brake cooling oil
HD465-8, HD605-8 40-239

FAILURE CODE [2F00KM] 40 TROUBLESHOOTING

Action level Failure code Parking Brake Dragging
Failure
Details of fail-
Machine is moved when the parking brake switch is in the "PARK" position.
ure
Action of con-
None in particular
troller
Effect to the
If the machine is used as it is, damage to the parking brake is possible.
machine
q If failure code [D1EMKA], [D1EMKB], [DW4BK4], or [DW4BMA] is also displayed, troubleshoot for it first.
q One or more failure codes [DAQQKR], [DAQRKR], [DB1QKR], and [DB1RKR] indicates unsatisfactory CAN com-
Related infor- munication between the transmission controller and the retarder and hoist controller. Troubleshoot for it (them) first.
mation q If the accumulator pressure is too low, you cannot release the parking brake.

Wrong operation of the q Set parking brake switch to "RELEASE" before you move the machine.
1
parking brake switch q While you move the machine, do not use the parking brake.

2. Replace relay R26 with normal relay.
Is the problem corrected after parking brake safety relay R26 is replaced?
Result when Relay R26 is

The machine is back to normal.
relay R26 is defective.
Defective parking brake
2 replaced
safety relay Relay R26 is
relay R26 Machine is not back to normal.
normal.

2. Disconnect the connector, and connect T-adapter to the male side.
Resistance Between R26 (male) (1) and (2) 290±30 Ω

2. Disconnect connector PBS, and connect T-adapter to the male side.
Parking brake switch in
Max. 1 Ω
Between PBS (male) (5) and "TRAVEL"
Defective parking brake (4) Parking brake switch in
3 Min. 1 MΩ
switch "PARK"
Resistance
Parking brake switch in
Min. 1 MΩ
Between PBS (male) (5) and "TRAVEL"
(6) Parking brake switch in
Max. 1 Ω
"PARK"
4
40-240 HD465-8, HD605-8

Circuit diagram related to parking brake (with automatic idle stop function)
HD465-8, HD605-8 40-241

FAILURE CODE [2F00KM] 40 TROUBLESHOOTING
Circuit diagram related to parking brake (without automatic idle stop function)
40-242 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [2G42ZG]
FAILURE CODE [2G42ZG]

Action level Failure code Accumulator Oil Pressure Low (Front)
Failure
L03 2G42ZG (Retarder and hoist controller system)
Details of fail- Signal (voltage 1.56 V or less) from the accumulator oil pressure sensor (front) indicates a drop in oil pressure
ure (13.2 MPa {135 kg/cm2} or less).
Action of con-
None in particular
troller
Effect to the
If the machine is used as it is, the front brake may not operate.
machine
Related infor-
mation

Hydraulic system (pump, relief valve, or piping) may be defective. If pressure is too low,
1 Hydraulic system failure
examine and remove the cause of failure.

Defective front accumula- 2. Put T-adapter into connector ACCF.
2 3. Turn the start switch to the ON position
tor oil pressure sensor
Voltage Between ACCF (2) and (1) 0.3 to 4.7 V
Defective retarder and If there is no failure with the checks above, the retarder and hoist controller is defective.
3
hoist controller (Since this is an internal problem, you cannot troubleshoot.)
Circuit diagram related to accumulator oil pressure sensor (front)
HD465-8, HD605-8 40-243

FAILURE CODE [2G43ZG] 40 TROUBLESHOOTING
FAILURE CODE [2G43ZG]

Action level Failure code Accumulator Oil Pressure Low (Rear)
Failure
L03 2G43ZG (Retarder and hoist controller system)
Details of fail- Signal (voltage 1.21 V or less) from the accumulator oil pressure sensor (rear) senses a drop in oil pressure
ure (8.8 MPa {90 kg/cm2} or less).
Action of con-
None in particular
troller
Effect to the
If the machine is used as it is, the rear brake may not operate.
machine
Related infor-
mation

Hydraulic system (pump, relief valve, or piping) may be defective. If pressure is too low,
1 Hydraulic system failure
examine and remove the cause of failure.

Defective rear accumula- 2. Put T-adapter into connector ACCR.
Voltage Between ACCR (2) and (1) 0.3 to 4.7 V
3
Circuit diagram related to accumulator oil pressure sensor (rear)
40-244 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [6014NX]
FAILURE CODE [6014NX]

Action level Failure code Hydraulic Oil Filter Clogging
Failure
L01 6014NX (Machine monitor system)
Details of fail- When the torque converter oil temperature is above 50 °C, the signal circuit of the hydraulic oil filter switch is
ure opened (disconnected from GND).
Action of con-
None in particular
troller
Effect to the
If the machine is used as is, damage to the hydraulic system is possible.
machine
q The monitor function examines the S/T hoist filter switch input signal. (Code: 04510)
Related infor- (Normal: OFF, blockage: ON)

Hydraulic Oil Filter Block-
1 Make sure the hydraulic oil filter is not clogged. If it is clogged, clean or replace it.
age

2. Disconnect connector SHOF, and connect T-adapter to the male side.
Defective hydraulic oil filter 3. Turn the start switch to the ON position
2
switch
Between SHOF (male) (1) When filter is normal Max. 1 Ω
Resistance

2. Disconnect connector MCM1 and SHOF, and connect T-adapter to each female side.
3
ness Between MCM1 (female) (49) and SHOF (female) (1) Max. 1 Ω
Resistance
Between MCM1 (female) (13) and SHOF (female) (2) Max. 1 Ω

Defective monitor control- When filter is normal Max. 1 V
ler Voltage
(13) When the filter is clogged 6 to 12 V
If there is no failure with the checks above, the monitor controller is defective. (Since this
is an internal problem, you cannot troubleshoot.)
Circuit diagram related to the hydraulic oil filter blockage
HD465-8, HD605-8 40-245

FAILURE CODE [879AKA] 40 TROUBLESHOOTING
FAILURE CODE [879AKA]

Action level Failure code A/C Recirculation Air Temperature Sensor Open Circuit
Failure
- 879AKA (Machine monitor system)
Details of fail-
Air conditioner controller senses open circuit in the recirculation air temperature sensor.
ure
q Air conditioner controller transmits open circuit information of recirculation air temperature sensor to mon-
Action of con-
itor controller by CAN communication.
troller
q Stops air conditioner when in automatic air conditioner mode.
Since air conditioner recirculation air temperature sensor has open circuit, automatic air conditioner does not
Effect to the
operate.
machine
(Air conditioner is operable in manual mode)
mation Procedure: Turn the start switch to the ON position
No. Cause Procedure, measuring location, criteria and remarks

Defective air conditioner Air conditioner controller is defective. (Since this is an internal problem, you cannot trou-
1
controller bleshoot.)
Defective air conditioner If there is no failure with the checks above, the air conditioner unit is defective. (Since this
2
unit is an internal problem, you cannot troubleshoot.)
40-246 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [879AKB]
FAILURE CODE [879AKB]

Action level Failure code A/C Recirculation Air Temperature Sensor Short Circuit
Failure
- 879AKB (Machine monitor system)
Details of fail-
Air conditioner controller senses short circuit in the recirculation air temperature sensor.
ure
q Air conditioner controller transmits short circuit information of recirculation air temperature sensor to mon-
Action of con-
itor controller by CAN communication.
troller
q Stops air conditioner when in automatic air conditioner mode.
Since air conditioner recirculation air temperature sensor has short circuit, automatic air conditioner does not
Effect to the
operate.
machine
(Air conditioner is operable in manual mode)

1
2
HD465-8, HD605-8 40-247

FAILURE CODE [879BKA] 40 TROUBLESHOOTING
FAILURE CODE [879BKA]

Action level Failure code A/C Fresh Air Temperature Sensor Open Circuit
Failure
L01 879BKA (Machine monitor system)
Details of fail-
Air conditioner controller senses open circuit in the ambient temperature sensor.
ure
q Air conditioner controller transmits open circuit information of the ambient temperature sensor to monitor
Action of con- the controller by CAN communication.
troller q Ignores data of the ambient temperature sensor and continues control of the air conditioner in automatic
air conditioner mode.
Since air conditioner ambient temperature sensor has open circuit, external air temperature is not considered
Effect to the
in automatic air conditioner mode.
machine
(No effect on the air conditioner in manual mode.)

Defective ambient temper- 2. Disconnect connector AATS, and measure it at the male side.
1
ature sensor Between AATS (male) (1) Approx. 1.7
Resistance Temperature: 25 °C
and (2) kΩ

2. Disconnect connectors AC1 and AATS, and measure it at each female side.
2
ness Between AC1 (female) (3) and AATS (female) (1) Max. 1 Ω
Resistance
Between AC1 (female) (4) and AATS (female) (2) Max. 1 Ω
Defective air conditioner If there is no failure with the checks above, the air conditioner controller is defective.
3
controller (Since this is an internal problem, you cannot troubleshoot.)
4
unit (Since this is an internal problem, you cannot troubleshoot.)
Circuit diagram related to air conditioner ambient temperature sensor
40-248 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [879BKB]
FAILURE CODE [879BKB]

Action level Failure code A/C Fresh Air Temperature Sensor Short Circuit
Failure
L01 879BKB (Machine monitor system)
Details of fail-
Air conditioner controller senses short circuit in the ambient temperature sensor.
ure
q Air conditioner controller transmits short circuit information of the ambient temperature sensor to monitor
Action of con- the controller by CAN communication.
troller q Ignores data of the ambient temperature sensor and continues control of the air conditioner in automatic
air conditioner mode.
Since air conditioner ambient temperature sensor has short circuit, external air temperature is not considered
Effect to the
in automatic air conditioner mode.
machine
(Air conditioner, no effect in manual mode.)

Defective ambient temper- 2. Disconnect connector AATS, and measure it at the male side.
1
ature sensor Between AATS (male) (1) Approx. 1.7
Resistance Temperature: 25 °C
and (2) kΩ

Ground fault in wiring har- 2. Disconnect connectors AC1 and AATS.
2
ness Between ground and AC1 (female) (3) or AATS (female)
(1)

Short circuit in wiring har- 2. Disconnect connectors AATS and AC1.
3
ness Between AC1 (female) (3) and (4), or between AATS
(female) (1) and (2)
4
5
HD465-8, HD605-8 40-249

FAILURE CODE [879BKB] 40 TROUBLESHOOTING
Circuit diagram related to air conditioner ambient temperature sensor
40-250 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [879CKA]
FAILURE CODE [879CKA]

Action level Failure code Ventilating Sensor Open Circuit
Failure
- 879CKA (Machine monitor system)
Details of fail-
Air conditioner controller senses open circuit in evaporator temperature (frost) sensor.
ure
q Air conditioner controller transmits open circuit information of evaporator temperature (frost) sensor to
Action of con-
monitor the controller by CAN communication.
troller
q Stops air conditioner.
Effect to the
Air conditioner does not operate because of open circuit in evaporator temperature (frost) sensor.
machine

1
2
HD465-8, HD605-8 40-251

FAILURE CODE [879CKB] 40 TROUBLESHOOTING
FAILURE CODE [879CKB]

Action level Failure code Ventilating Sensor Short Circuit
Failure
- 879CKB (Machine monitor system)
Details of fail-
Air conditioner controller senses short circuit in evaporator temperature (frost) sensor.
ure
q Air conditioner controller transmits short circuit information of evaporator temperature (frost) sensor to
Action of con-
monitor the controller by CAN communication.
troller
q Stops air conditioner.
Effect to the
Air conditioner does not operate because of short circuit in evaporator temperature (frost) sensor.
machine

1
2
40-252 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [879EMC]
FAILURE CODE [879EMC]

Action level Failure code Ventilation Damper Malfunction
Failure
L01 879EMC (Machine monitor system)
Details of fail- Air conditioner controller senses no rotation of vent selector (mode) damper servomotor. It judges from the
ure potentiometer voltage of servomotor.
Action of con- Air conditioner controller transmits the problem of the vent selector (mode) damper to the monitor controller
troller by CAN communication.
Effect to the
You cannot select Vent (mode), but the air conditioner operates.
machine

1
2
HD465-8, HD605-8 40-253

FAILURE CODE [879FMC] 40 TROUBLESHOOTING
FAILURE CODE [879FMC]

Action level Failure code Air Mix Damper Malfunction
Failure
L01 879FMC (Machine monitor system)
Details of fail- The air conditioner controller senses no rotation of air mix (temperature control) damper servomotor. It judges
ure from the potentiometer voltage of the servomotor.
Action of con- Air conditioner controller transmits a problem of the air mix damper to the monitor controller by CAN commu-
troller nication.
Effect to the
Air conditioner does not operate, since you cannot regulate the temperature.
machine

1
2
40-254 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [879GKX]
FAILURE CODE [879GKX]

Action level Failure code Refrigerant Pressure Input Signal Out of Range
Failure
L01 879GKX (Machine monitor system)
Details of fail-
Air conditioner controller sensed that dual pressure switch is "OFF" (incorrect).
ure
q Air conditioner controller transmits problem information of refrigerant pressure to the monitor controller by
Action of con- CAN communication.
troller q Air conditioner controller turns OFF the compressor clutch relay since refrigerant pressure is incorrect.
(Air conditioner compressor stops)
Effect to the
Air conditioner does not function (in cool mode).
machine

See Chapter 80 APPENDIX, "TEST (DUAL) PRESSURE SWITCH FOR REFRIGER-
ANT".
Defective refrigerant (dual) NOTICE
1
pressure switch
Before you replace dual pressure switch, collect the refrigerant. See Chapter 80 AP-
PENDIX, "PRECAUTIONS FOR REFRIGERANT".

2. Disconnect connectors AC1 and HLS.
2
ness Between HLS (female) (1) and AC1 (female) (5) Max. 1 Ω
Resistance
Between HLS (female) (2) and ground Max. 1 Ω
3
4
Circuit diagram related to refrigerant (dual) pressure switch
HD465-8, HD605-8 40-255

FAILURE CODE [989D00] 40 TROUBLESHOOTING
FAILURE CODE [989D00]

Action level Failure code Gradient Caution
Failure
- 989D00 (Retarder and hoist controller system)
Details of fail-
Dump body is lifted with the machine tilted.
ure
Action of con- q Illuminates the tilt caution lamp.
troller q Illuminates the centralized warning lamp and operates the alarm buzzer.
Effect to the
If the dump body is lifted further, the machine may fall.
machine
Related infor-
mation

Do not raise the dump body when the machine is tilted 15 ° or more. (Instruct the operator
1 Wrong operation
on correct operation of machine.)

2. Put T-adapter into connector T10A.
2 Defective tilt angle sensor 3. Turn the start switch to the ON position
Between T10A (B) and (A)
Voltage 2.2 to 2.8 V
With the machine on level ground and stopped
3
Circuit diagram related to retarder and hoist controller
40-256 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [989L00]
FAILURE CODE [989L00]

Action level Failure code Engine Controller Lock Caution 1
Failure
- 989L00 (Machine monitor system)
Details of fail-
Engine controller lock up is sensed (Cause 1).
ure
Action of con-
None in particular
troller
Effect to the
Engine does not start.
machine
q If the failure code is shown after you replace the machine monitor, it is necessary to change the operator
Related infor- password back to the previous one.
Procedure: Turn the start switch to the ON position

Monitor-controller replace-
1 This failure may occur because of monitor-controller replacement.
ment
HD465-8, HD605-8 40-257

FAILURE CODE [989M00] 40 TROUBLESHOOTING
FAILURE CODE [989M00]

Failure
- 989M00 (Machine monitor system)
Details of fail-
ure
Action of con-
None in particular
troller
Effect to the
machine
q If the failure code is shown after you replace the machine monitor, it is necessary to change the operator
Related infor- password to be the previous one.

Monitor-controller replace-
1 This failure may occur because of the monitor controller replacement.
ment
Defective monitor control- If this failure code is shown, although the monitor controller is not replaced, failure in the
2
ler monitor controller may occur. (Since this is an internal defect, you cannot troubleshoot)
40-258 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [989N00]
FAILURE CODE [989N00]

Failure
- 989N00 (Machine monitor system)
Details of fail-
ure
Action of con-
Tries to recover automatically.
troller
Effect to the
machine
mation Procedure: Failure code is not caused again, since machine recovers when cause of failure disappears.

If this occurs again and again, engine controller may be defective. (Since this is an inter-
1 Defective engine controller
nal problem, you cannot troubleshoot.)
HD465-8, HD605-8 40-259

FAILURE CODE [989X00] 40 TROUBLESHOOTING
FAILURE CODE [989X00]

Action level Failure code Overspeed Warning
Failure
- 989X00 (Transmission controller system)
Details of fail- Travel speed exceeds the speed set by the maximum speed limit, and has no limit by the accelerator control
ure alone.
Action of con- q Operate the alarm.
troller q Operates the retarder brake by the retarder and hoist controller.
Effect to the
The travel speed is reduced to the set speed by the retarder and hoist control.
machine
When the speed has no limit with only the accelerator correction with the transmission controller, while the
Related infor-
speed limit works. The travel speed has a limit when the retarder brake works by the retarder and hoist con-
mation
troller.

Although the speed limit works, release the accelerator pedal during downhill travel.
1 Wrong operation
(Instruct operators on the proper operating procedures.)
40-260 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [989Y00]
FAILURE CODE [989Y00]

Action level Failure code Overload Warning
Failure
- 989Y00 (Transmission controller system)
Details of fail-
The machine travels at a speed of 4 km/h or higher while the payload exceeds specified level.
ure
q Operate the alarm.
Action of con-
q The transmission controller and the retarder and hoist controller control the accelerator and retarder and
troller
in that sequence control the travel speed.
Effect to the
The travel speed has a limit until you dump your load.
machine
Related infor-
The speed has a limit during over load. It is set at 15 km/h.
mation

Do not load when the PLM external display lamp flashes.
1 Wrong operation
(Instruct operators on the proper operating procedures.)
Calibration trouble of load When the measured mass by a gravimeter does not indicate over load, examine the sus-
2
meter pension and calibrate the load meter.
HD465-8, HD605-8 40-261

FAILURE CODE [A1U0N3] 40 TROUBLESHOOTING
FAILURE CODE [A1U0N3]

Action level Failure code HC Desorb Request 1
Failure
L01 A1U0N3 (Engine controller system)
Details of fail-
Fuel not burned remains in KDPF because the engine runs at low idle speed or low load for a long time.
ure
Action of con- Requests an operator to perform the manual stationary regeneration (dry the fuel), or informs that the manual
troller stationary regeneration (to dry fuel) is in progress.
Effect to the Same event as automatic regeneration occurs. (When the machine is in a safe condition, machine controls
machine the engine speed to stay up around 1000 rpm.)
k KDPF and KDOC become hot (Minimum 500 °C). Be careful not to become burned.
q If the failure code [CA3313], [CA3314], [CA3315], [CB3313], [CB3314], or [CB3315] is displayed, perform
troubleshooting for the displayed failure code.
q All of KDOC input, KDOC output, and KDPF output temperatures during idle (non-regeneration) are ap-
proximately 100 to 250 °C. Each temperature difference is approximately 10 °C. (KDOC input temperature
> KDOC output temperature > KDPF output temperature).
q When manual stationary regeneration is performed due to the guidance of monitor displaying the failure
Related infor- code [A1U0N3] or [A1U0N4], fuel dosing is disabled. Accordingly, each temperature of KDOC inlet,
mation KDOC outlet, and KDPF outlet reaches to approximately 250 to 400 °C.
q When manual stationary regeneration except above is in progress, KDOC input temperature is approxi-
mately 250 to 400 °C. KDOC output temperature and KDPF output temperature are approximately 450 to
600°C.
q The difference between KDOC input and output temperatures is large, when KDPF is completely cool or
engine runs at low idle speed (without regenerating KDPF). Replace KDOC input or output temperature
sensors. Whichever is thought to be defective, when you judge from KDPF output temperature.

Manual stationary regener-
1. Perform the instructions on the monitor for manual stationary regeneration.
1 ation performed (to dry
KDPF) 2. If this failure code is removed after this, repair work is done.
This failure code is displayed if the connectors of electrical parts around the engine are
defective, disconnected, or loosened due to heat and vibration. See descriptions of wiring
Defective wiring harness
2 harnesses and connectors in the table "Electrical equipment" in "CHECKS BEFORE
connector
TROUBLESHOOTING" under "RELATED INFORMATION ON TROUBLESHOOTING",
and check the connectors.
When KDPF is cool or there are important differences between KDOC input, KDPF out-
put, or KDPF output temperature at idle (non-regeneration), change the sensor.
REMARK
Defective KDOC inlet tem- q Temperature detected by KDOC inlet temperature sensor can be checked by the
3 monitoring function. (Code: 47300 and 47302)
perature sensor
q Temperature detected by KDOC outlet temperature sensor can be checked by the
monitoring function. (Code: 47400 and 47402)
q Temperature detected by KDPF outlet temperature sensor can be checked by the
The KDOC input temperature is approximately 250 °C or below during manual stationary
regeneration. The VGT solenoid current remains approximately 1000 mA although sev-
eral hours have passed. The manual stationary regeneration does not complete. The VGT
4 Defective VGT is defective.
REMARK
Temperature detected by KDOC inlet temperature sensor can be checked by the monitor-
ing function. (Code: 47300 and 47302)
If there is no failure with the checks above, the engine controller is defective. (Since this is
an internal problem, you cannot troubleshoot.)
40-262 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [A1U0N4]
FAILURE CODE [A1U0N4]

Action level Failure code HC Desorb Request 2
Failure
L03 A1U0N4 (Engine controller system)
Details of fail-
Fuel not burned remains in KDPF because the engine runs at low idle speed or low load for a long time.
ure
Action of con- Requests an operator to perform the manual stationary regeneration (dry the fuel), or informs that the manual
troller stationary regeneration (to dry fuel) is in progress.
Effect to the Same event as automatic regeneration occurs. (When the machine is in a safe condition, machine controls
machine the engine speed to stay up around 1000 rpm.)
q If the failure code [CA3313], [CA3314], [CA3315], [CB3313], [CB3314], or [CB3315] is displayed, perform
troubleshooting for the displayed failure code.
q All of KDOC input and output temperatures, and KDPF output temperature during idle (non-regeneration)
are approximately 100 to 250 °C. Each temperature difference is approximately 10 °C. (KDOC input tem-
perature > KDOC output temperature > KDPF output temperature).
q When manual stationary regeneration is performed due to the guidance of monitor displaying the failure
code [A1U0N4] or [A1U0N3], fuel dosing is disabled. Accordingly, each temperature of KDOC inlet,
Related infor- KDOC outlet, and KDPF outlet reaches to approximately 250 to 400 °C.
mation q When manual stationary regeneration (except above) is in progress, KDOC input temperature is approx-
imately 250 to 400 °C. The KDOC output temperature and KDPF output temperature are approximately
450 to 600 °C.
q There is a large difference between KDOC input and output temperatures when KDPF is completely cool.
Or when the engine runs at low idle speed (without KDPF regeneration). Replace the KDOC input or out-
put temperature sensor, whichever is thought to be defective, because of the KDPF output temperature.
q After the repair is completed, make sure that this failure code and failure code [A1U0N3] are removed with
the procedure that follows.

Manual stationary regener-
1. Use the instruction on the monitor to perform manual stationary regeneration.
1 ation performed (to dry
KDPF) 2. If this failure code is removed after this, repair work is done.
connector
When KDPF is cool or there are important differences between KDOC input, KDPF out-
put, or KDPF output temperature at idle (non-regeneration), change the sensor.
REMARK
3 monitoring function. (Code: 47300 and 47302)
perature sensor
q Temperature detected by KDPF outlet temperature sensor can be checked by the
The KDOC input temperature is approximately 250 °C or below during manual stationary
regeneration. The VGT solenoid current remains approximately 1000 mA although sev-
eral hours have passed. The manual stationary regeneration does not complete. The VGT
4 Defective VGT is defective.
REMARK
HD465-8, HD605-8 40-263

FAILURE CODE [A1U0N4] 40 TROUBLESHOOTING

40-264 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [AA10NX]
FAILURE CODE [AA10NX]

Action level Failure code Air Cleaner Clogging
Failure
L01 AA10NX (Machine monitor system)
Details of fail-
When the engine runs, the air cleaner switch signal circuit is opened (disconnected from GND).
ure
Action of con- q Illuminates the air cleaner blockage caution lamp.

troller q If the cause of failure is eliminated, the machine goes back to normal.
Effect to the
If the machine is used as it is, the air intake capacity of the engine may decrease.
machine
mation Procedure: Start the engine.
Clogged air cleaner (when Dust gauge does not indicate in the red
Air cleaner is normal.
1 the system operation is area.
correct) Dust gauge indicates in the red area. Air cleaner is clogged.

2. Disconnect connector FR01, and connect T-adapter to the male side.
REMARK
q Examine the operation of the air cleaner switch with the monitor function. (Code:
04510)
Defective air cleaner
2 q Air cleaner intake resistance
clogged sensor
*1: Max. -3430 Pa {Max. -350 mmH2O}
*2: -7470±490 Pa {-762±50 mmH2O}
When air cleaner is normal
Max. 1 Ω
Between FR01 (male) (1) *1
Resistance
and (2) When air cleaner is clogged
Min. 1 MΩ
*2

2. Disconnect connectors MCM1 and FR01, and connect T-adapter to each female side.
3
ness Between MCM1 (female) (53) and FR01 (female) (2) Max. 1 Ω
Resistance
Between MCM1 (female) (13) and FR01 (female) (1) Max. 1 Ω

2. Insert T-adapter into connector MCM1.
Defective monitor control- Air cleaner is normal. Max. 1 V
ler Voltage
(13) Air cleaner is clogged. 6 to 12 V
HD465-8, HD605-8 40-265

FAILURE CODE [AA10NX] 40 TROUBLESHOOTING
Circuit diagram related to air cleaner sensor
40-266 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [AB00KE]
FAILURE CODE [AB00KE]

Action level Failure code Charge Voltage Low
Failure
L03 AB00KE (Transmission controller system)
Details of fail-
Generation signal is not input from the alternator while engine is running.
ure
Action of con-
None in particular
troller
Effect to the
If the machine is used as it is, the power supply voltage can fall too low for the machine to operate.
machine
Related infor-
Measure battery voltage level with the monitor function. (Code: 04307)
mation

Loose alternator connec-
1 tor or open circuit in the
connection. 2. Examine terminals
Start the engine.

2 Defective alternator Between alternator terminal Engine rotation: Moderate or 27.5 to 29.5
Voltage
R and ground higher V

Open circuit in wiring har- 2. Disconnect connector ATC1 and alternator connection R. Connect T-adapter to
3 female side of ATC1.
ness
Resistance Between ATC3 (female) (15) and alternator connection R Max. 1 Ω

2. Disconnect connectors BRC1, MCM1, E02B, E02A, JPS, D02, ATC1, and alternator
Ground fault in wiring har- connection R, and connect T-adapter to female side of ATC1.
4
ness
Between ground and ATC1 (female) (15) or alternator con-
nection R

2. Disconnect connectors ATC1, BRC1, and MCM1, and connect T-adapter to each
female side.
Between ATC1 (female) (15) and each pin other than pin
Short circuit in wiring har- Open circuit
5 (15)
ness
Continuous Between BRC1 (female) (15) and each pin other than pin
Open circuit
circuit (15)
Between MCM1 (female) (6) and each pin other than pin
Open circuit
(6)
6
HD465-8, HD605-8 40-267

FAILURE CODE [AB00KE] 40 TROUBLESHOOTING
Circuit diagram related to alternator
40-268 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [AB00KY]
FAILURE CODE [AB00KY]

Action level Failure code Alternator R Terminal Hot Short Circuit
Failure
L03 AB00KY (Transmission controller system)
Details of fail- Before, when the start switch was turned to OFF, the signal of the alternator connection R was turned ON.
ure (The next time the start switch is turned to ON, a failure is generated.)
Action of con-
None in particular
troller
Effect to the
If the machine is used as it is, the power supply voltage can fall too low for the machine to operate.
machine
Related infor-
Measure battery voltage level with the monitor function. (Code: 04307)
mation

Hot short circuit in wiring 2. Disconnect connector ATC1, and connect T-adapter to the female side.
harness
Voltage Between ATC1 (female) (15) and ground Max. 1 V
2
HD465-8, HD605-8 40-269

FAILURE CODE [AQ00N3] 40 TROUBLESHOOTING
FAILURE CODE [AQ00N3]

Action level Failure code KDPF System Imbalance Soot Accumulation 1
Failure
- AQ00N3 (Engine controller system)
Details of fail- Since soot accumulation between two KDPFs is not equal, a difference of gas flow rate is generated
ure between two after treatment systems.
Action of con-
Lowers regeneration temperature than normal temperature during regeneration.
troller
Effect to the
None in particular
machine
Related infor- k KDPF and KDOC become hot (Minimum 500 °C). Be careful not to become burned.
mation If this failure code and [AQ00N4] are displayed without other failure codes, troubleshooting is not required.

If this failure code is displayed with [DHACMA] or [DHADMA], the cause of the failure
code is cleared after freeze is solved. Troubleshooting is not required.
1 Freeze REMARK
If failure code [CA3135] or [CB3135] is shown, or is recorded in the Problem Record, first
troubleshoot for failure code [CA3135] or [CB3135]. If the KDPF difference pressure sen-
sor is replaced, replace the two KDPF pressure sensors each one installed in two after
Defective KDPF difference treatment systems.
2
pressure sensor pipe REMARK
To access KDPF differential pressure sensor, the wiring harness, and tube, see DISAS-
SEMBLY AND ASSEMBLY, "REMOVE AND INSTALL KDPF ASSEMBLY" and "DISAS-
SEMBLE AND ASSEMBLE OF KDPF ASSEMBLY".
If failure code [CA1921], [CA1922], [CA2639], [CA5383], [CB1921], [CB1922], [CB2639],
or [CB5383] is displayed, perform troubleshooting for failure code [CA1921], [CA1922],
Not equal soot accumula-
3 [CA2639], [CA5383], [CB1921], [CB1922], [CB2639], or [CB5383] first. If KDPF is
tion
replaced or cleaned, replace and clean the two KDPFs each one attached to two after
treatment systems.
40-270 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [AQ00N4]

Action level Failure code KDPF System Imbalance Soot Accumulation 2
Failure
- AQ00N4 (Engine controller system)
Details of fail- Since soot accumulation between two KDPFs is not equal, a difference of gas flow rate is generated
ure between two after treatment systems.
Action of con- Lowers regeneration temperature than normal temperature during regeneration (lowers temperature than
troller that when the failure code AQ00N3 occurs).
Effect to the
None in particular
machine
Related infor- k KDPF and KDOC become hot (Minimum 500 °C). Be careful not to become burned.
mation If this failure code and [AQ00N3] are displayed without other failure codes, troubleshooting is not required.

If this failure code is displayed with [DHACMA] or [DHADMA], the cause of the failure
code is cleared after freeze is solved. Troubleshooting is not required.
1 Freeze REMARK
If failure code [CA3135] or [CB3135] is shown, or is recorded in the Problem Record, first
troubleshoot for failure code [CA3135] or [CB3135]. If the KDPF difference pressure sen-
sor is replaced, replace the two KDPF pressure sensors each one installed in two after
Defective KDPF difference treatment systems.
2
pressure sensor pipe REMARK
If failure code [CA1921], [CA1922], [CA2639], [CA5383], [CB1921], [CB1922], [CB2639],
or [CB5383] is displayed, perform troubleshooting for failure code [CA1921], [CA1922],
Not equal soot accumula-
3 [CA2639], [CA5383], [CB1921], [CB1922], [CB2639], or [CB5383] first. If KDPF is
tion
replaced or cleaned, replace and clean the two KDPFs each one attached to two after
treatment systems.
HD465-8, HD605-8 40-271

FAILURE CODE [AQ10N3] 40 TROUBLESHOOTING

Action level Failure code Manual Stationary Regeneration Request (KDOC Face Plugging)
Failure
L01 AQ10N3 (Engine controller system)
The Manual Stationary Regeneration Request (KDOC) requires the operator to perform manual stationary
regeneration to recover efficient operation, efficient KDOC (catalyst procedure). The soot in KCSF does not
Details of fail-
burn correctly because the KDOC input temperature in regeneration is usually about 250 to 400 °C. The
ure
KDOC output temperature is usually approximately 450 to 600 °C, but the KDOC output temperature does
not rise.
Action of con-
Stops the fuel dosing.
troller
Effect to the
None in particular
machine
q Temperature detected by KDOC inlet temperature sensor can be checked by the monitoring function.
(Code: 47300 and 47302)
q Temperature detected by KDOC outlet temperature sensor can be checked by the monitoring function.
(Code: 47400 and 47402)
q Temperature detected by KDPF outlet temperature sensor can be checked by the monitoring function.
(Code: 47200 and 47202)
q To start the engine again, wait until system operating lamp goes out after you Turn the start switch to
the OFF position. Then turn the start switch to the ON position
q All of KDOC input and output temperatures, and KDPF output temperature during idle (non-regenera-
tion) are approximately 100 to 250 °C. Each temperature difference is approximately 10 °C. (KDOC in-
Related infor- put temperature > KDOC output temperature > KDPF output temperature).
mation q Since KDOC Face Plugging ([CA2637], [CB2637]) was detected repeatedly, the failure code [AQ10N3]
prompts the user to perform the manual stationary regeneration.
q Manual stationary regeneration (KDOC Face blockage) does not perform the fuel dose to be efficient
and recover the KDOC. The KDOC input and output temperatures, and KDPF output temperature are
approximately 250 to 400 °C.
How to Perform Manual Stationary Regeneration
2. Perform the stationary regeneration by following the screen for the stationary regeneration displayed on
the monitor screen.
REMARK
Time necessary for the manual stationary regeneration effect to Manual Stationary Regeneration Request
(KDOC caused a blockage) is approximately 1.5 hours.

If this failure code is shown on the machine monitor for several hours after manual station-
1 Defective engine controller ary regeneration is performed, the engine controller is defective. Since this is an internal
problem, you cannot troubleshoot. Replace the assembly.
40-272 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [B@BAZG]
FAILURE CODE [B@BAZG]

Action level Failure code Eng Oil Press Low
Failure
L03 B@BAZG (Engine controller system)
Details of fail- There is a drop in the signal voltage from the engine oil pressure sensor when the engine operates. Then
ure the engine controller senses an unusual drop in the engine oil pressure.
Action of con- q Illuminates up the engine oil pressure monitor in red on the machine monitor.
troller q Derates the engine power for operation.
Effect to the q Engine power decreases.
machine q If the machine is used as is, the engine may seize.
q Engine oil pressure can be checked by the monitoring function. (Code: 37200)
Related infor-
mation
1. An engine oil pressure drop is sensed. Check the engine oil, referring to TEST AND
Low engine oil pressure ADJUST, "TEST ENGINE OIL PRESSURE".
1 (when the system opera- 2. Troubleshoot for "Oil Pressure Drops" in S mode.
tion is correct) 3. In the case of excessive consumption of engine oil, perform troubleshooting for
"ENGINE OIL CONSUMPTION IS EXCESSIVE" in S mode.
Defective engine oil pres- If no failure is found by the above checks on cause 1, engine oil pressure sensor system
2
sure sensor system may be defective. Perform troubleshooting for failure codes [CA135] and [CA141].
HD465-8, HD605-8 40-273

FAILURE CODE [B@BAZK] 40 TROUBLESHOOTING
FAILURE CODE [B@BAZK]

Action level Failure code Engine Oil Level Low
Failure
L01 B@BAZK (Machine monitor system)
Details of fail-
Signal circuit of the engine oil level switch is opened (disconnected from GND) when the engine is stopped.
ure
Action of con-
None in particular
troller
Effect to the
If the machine is used as it is, the engine may be seized.
machine
1. Since engine oil level drop is sensed, check engine oil level.
2. Troubleshoot for "Engine oil level Low" in S mode.
1 Engine oil level low
3. In the case of too much use of engine oil, troubleshoot for "Engine Oil Usage is Too
Much" in S mode.

2. Disconnect connector E04, and connect T-adapter to the male side.
Defective engine oil level
2
sensor Between E04 (male) (1) and Engine oil level is normal. Max. 1 Ω
Resistance
ground Engine oil level is low. Min. 1 MΩ

Open circuit in wiring har- 2. Disconnect connectors MCM1 and E04, and connect T-adapter to each female side.
3
ness
Resistance Between MCM1 (female) (69) and E04 (female) (1) Max. 1 Ω

Defective monitor control- Engine oil level is normal. Max. 1 V
ler Voltage
ground Engine oil level is low. 6 to 12 V
Circuit diagram related to engine oil level switch
40-274 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [B@BCNS]
FAILURE CODE [B@BCNS]

Action level Failure code Eng Water Overheat
Failure
L02 B@BCNS (Engine controller system)
Details of fail- There is a drop in voltage from the engine coolant temperature sensor when the engine is in operation. The
ure engine controller senses that the engine coolant is too hot.
Action of con- q Illuminates the engine coolant temperature monitor in red on the machine monitor.
machine q If the machine is used as is, the engine may seize.
Engine coolant is too hot

1 (when the system opera- Engine coolant is too hot. If the coolant is found too hot, repair the cause of failure.
Defective engine coolant If no failure is found by the above checks on cause 1, engine coolant temperature sensor
2
temperature sensor system system may be defective. Perform troubleshooting for failure codes [CA144] and [CA145].
HD465-8, HD605-8 40-275

FAILURE CODE [B@BCQA] 40 TROUBLESHOOTING
FAILURE CODE [B@BCQA]

Action level Failure code Engine Coolant Level Low
Failure
L02 B@BCQA (Machine monitor system)
q The starting switch was turned to ON position again when the machine is operated for more than 1 hour
Details of fail- without repair after failure code [B@BCZK] 1s shown.
ure q Signal circuit of the coolant level switch keeps open (disconnected from GND) when the engine is
stopped.
Action of con-
Lights up the radiator coolant level caution lamp.
troller
Effect to the
If the machine is used as it is, the engine may overheat.
machine
Related infor- After the repair is completed, check that the failure code is cleared by the following procedure.
mation Procedure: Turn the starting switch to ON position.

Check whether radiator coolant level is normal.
NOTICE
1 Low radiator coolant level
If radiator coolant level is lowered, check periphery of engine and radiator for leak-
age before refilling.
1. Perform check and cleaning of the radiator coolant sensor directly since the float may
be stuck due to dust clogging.
Defective coolant level 3. Disconnect connector FL02, and connect T-adapter to the male side.
2
switch
Radiator coolant level is nor-
Between FL02 (male) (1) Max. 1 Ω
Resistance mal.
and ground
Radiator coolant level is low. Min. 1 MΩ

2. Disconnect connectors MCM1 and FL02, and connect T-adapter to each female side.
3
ness Between MCM1 (female) (48) and FL02 (female) (1) Max. 1 Ω
Resistance
Between MCM1 (female) (13) and FL02 (female) (2) Max. 1 Ω

2. Insert T-adapter into connector MCM1.
Defective monitor control- Radiator coolant level is nor-

4 Between MCM1 (48) and Max. 1 V
ler Voltage mal.
(13)
Radiator coolant level is low. 6 to 12 V
If no failure is found by the above checks, the monitor controller is defective. (Since this is
an internal defect, troubleshooting cannot be performed.)
40-276 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [B@BCQA]
Circuit diagram related to coolant level
HD465-8, HD605-8 40-277

FAILURE CODE [B@BCZK] 40 TROUBLESHOOTING
FAILURE CODE [B@BCZK]

Action level Failure code Engine Coolant Level Low
Failure
L01 B@BCZK (Machine monitor system)
Details of fail-
Signal circuit of the coolant level switch is opened (disconnected from GND) when the engine is stopped.
ure
Action of con-
Lights up the radiator coolant level caution lamp.
troller
Effect to the
If the machine is used as is, the engine may become too hot.
machine

Make sure radiator coolant level is normal.
NOTICE
1 Low radiator coolant level
If the radiator coolant level is low, look around the engine and radiator for leakage
before you fill it.
1. Examine and clean the radiator coolant sensor directly, since the level gauge can
become stuck because of the dust blockage.
Defective coolant level 3. Disconnect connector FL02, and connect T-adapter to the male side.
2
switch
Radiator coolant level is nor-
Between FL02 (male) (1) Max. 1 Ω
Resistance mal.
and ground
Radiator coolant level is low. Min. 1 MΩ

2. Disconnect connectors MCM1 and FL02, and connect T-adapter to each female side.
3
ness Between MCM1 (female) (48) and FL02 (female) (1) Max. 1 Ω
Resistance
Between MCM1 (female) (13) and FL02 (female) (2) Max. 1 Ω

Defective monitor control- Radiator coolant level is nor-

4 Between MCM1 (48) and Max. 1 V
ler Voltage mal.
(13)
Radiator coolant level is low. 6 to 12 V
40-278 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [B@BCZK]
Circuit diagram related to coolant level
HD465-8, HD605-8 40-279

FAILURE CODE [B@C7NS] 40 TROUBLESHOOTING
FAILURE CODE [B@C7NS]

Action level Failure code Retarder Oil Overheat (Rear)
Failure
L02 B@C7NS (Machine monitor system)
Details of fail-
The rear brake cooler oil is sensed as too hot (Minimum 120 °C)
ure
Action of con- q Illuminates the radiator oil over heat caution lamp.
Effect to the
If the machine is used as is, damage to the rear brake is possible.
machine
q The monitor function examines the temperature sensed by the retarder oil pressure sensor (rear). (Code:
30215)
Related infor-
q If failure code [DGR2KB] is also shown, troubleshoot for it first.
mation

Rear brake cooler oil too
1 Rear brake cooler oil is too hot, Investigate the cause and repair.
hot

2. Disconnect connector RTR, and connect T-adapter to the male side.
38.1 to 47.8
Oil temperature: 25 °C
kΩ
31.0 to 40.0
Defective retarder oil pres- Between RTR (male) (1) and Oil temperature: 30 °C
kΩ
2 (2) (Oil temperature sensor
sure sensor (rear)
Resistance heat properties) Oil temperature: 80 °C 6.1 to 7.0 kΩ
Oil temperature: 90 °C 4.6 to 5.2 kΩ
Between ground and RTR
Oil temperature: All range Min. 1 MΩ
(male) (1) or RTR (male) (2)
Defective retarder hoist If there is no failure with the checks above, the retarder and hoist controller is defective.
3
Defective monitor control- If there is no failure with the checks above, the monitor controller is defective. (Since this
4
ler is an internal problem, you cannot troubleshoot.)
40-280 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [B@C7NS]
Circuit diagram related to retarder oil overheat (rear)
HD465-8, HD605-8 40-281

FAILURE CODE [B@CENS] 40 TROUBLESHOOTING
FAILURE CODE [B@CENS]

Action level Failure code Power Train Oil Overheat
Failure
L02 B@CENS (Machine monitor system)
Details of fail-
Torque converter oil is sensed as too hot (Minimum 120 °C)
ure
Action of con- q Lights up the torque converter oil temperature caution lamp
q The monitor function examines the temperature sensed by torque converter oil temperature sensor.
Effect to the
(Code: 30100)
machine
q If the machine is used as is, there may be damage to the torque converter.
Related infor-
If failure code [DGT1KX] is also shown, troubleshoot for it first.
mation

The torque converter
1 Torque converter (power train) oil is too hot. When detected, repair the cause of failure.
(power train) oil is too hot

2. Disconnect connector T/C, T, and connect T-adapter to the male side.
38.1 to 47.8
kΩ
31.0 to 40.0
Between T/C, T (male) (1) Oil temperature: 30 °C
kΩ
Defective torque converter and (2) (Oil temperature
2
oil temperature sensor sensor heat properties) Oil temperature: 80 °C 6.1 to 7.0 kΩ
Resistance
Between ground and T/C,T
(male) (1) or T/C,T (male) Oil temperature: All range Min. 1 MΩ
(2)
Defective transmission If no failure is found by the above checks, the transmission controller is defective. (Since
3
controller this is an internal defect, troubleshooting cannot be performed.)
Defective monitor control- If no failure is found by the above checks, the monitor controller is defective. (Since this is
4
ler an internal defect, troubleshooting cannot be performed).
Circuit diagram related to power train oil overheat
40-282 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [B@JANS]
FAILURE CODE [B@JANS]

Action level Failure code Steering Oil Overheat
Failure
L02 B@JANS (Retarder and hoist controller system)
Details of fail-
The voltage of the steering oil temperature sensor signal circuit is 2.2 V (100 °C and higher) and lower.
ure
Action of con-
None in particular
troller
Effect to the
If the machine is used as it is, oil may leak.
machine
Related infor- The monitor function examines the input signal from the steering oil temperature sensor. (Code: 32701 (°C),
mation 32702 (V))

Overheating of steering oil
1 (when the system opera- Steering oil becomes too hot. If it is too hot, repair the cause of failure.
tion is correct)

2. Disconnect connector STR, and connect T-adapter to the male side.
38.1 to 47.8
kΩ
31.0 to 40.0
Defective steering oil tem- Between STR (male) (1) and Oil temperature: 30 °C kΩ
perature sensor
Between ground and STR
(male) (1) or STR (male) (2)
3
Circuit diagram related to steering oil temperature sensor
HD465-8, HD605-8 40-283

FAILURE CODE [CA115] 40 TROUBLESHOOTING
FAILURE CODE [CA115]

Action level Failure code Engine NE and Backup Speed Sensor Error
Failure
L04 CA115 (Engine controller system)
Details of fail-
Errors occur at the same time in the signal circuits of the NE speed sensor and the Bkup speed sensor.
ure
Action of con-
Stops the engine.
troller
Effect to the q Stopped engine cannot be started.
machine q Engine stops while the engine operates.
q When error occurs in the Bkup speed sensor power supply, Failure code [CA352] Sensor 1 Supply Volt-
age Low Error or Failure code [CA386] Sensor 1 Supply Voltage High Error is displayed, perform trouble-
shooting for it first.
Related infor- q An error occurs in the NE speed sensor power supply. Failure code [CA238] NE Speed Sensor Supply
mation Voltage Error or Failure code [CA239] NE Speed Sensor Supply Voltage High Error is shown. First trou-
bleshoot for that.

connector
Damages in the engine NE
Perform checks since the engine NE speed sensor installation may be defective (too
2 speed sensor or defective
loose).
installation
Defective installation of fly-
3 Perform checks since the flywheel installation may be defective (too loose).
wheel

2. Disconnect connectors ECM1 J1 and NE, and connect T-adapter to each female side.
Open circuit in wiring har- Between ECM1 J1 (female) (79) and NE (female) (1) Max. 1 Ω
4
ness
Resistance Between ECM1 J1 (female) (55) and NE (female) (2) Max. 1 Ω
Between ECM1 J1 (female) (31) and NE (female) (3) Max. 1 Ω

2. Disconnect connectors ECM1 J1 and NE, and connect T-adapter to either female
Ground fault in wiring har- side.
5
ness
Between ground and ECM1 J1 (female) (31) or NE
(female) (3)

Hot short circuit in wiring 2. Disconnect connector NE, and connect T-adapter to the female side.
harness
Voltage Between NE (female) (3) and ground Max. 1 V
40-284 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [CA115]

2. Disconnect connectors ECM1 J1 and NE, and connect T-adapter to either female
side.
Short circuit in wiring har-
7 Between ECM1 J1 (female) (79) and (31), or between NE
ness Min. 1 MΩ
Resistance
Between ECM1 J1 (female) (55) and (31), or between NE
Min. 1 MΩ
If there is no failure with the checks above, the engine NE speed sensor may be defective.
(Since this is an internal problem, you cannot troubleshoot.)
REMARK
Defective engine NE speed In normal condition, output from the speed sensor is pulse voltage of 5 V, which can-
8 q
sensor not be measured with a multimeter.
q Since the inside of the speed sensor consists of the hall sensor and electronic circuits,
not of coils, whether the speed sensor is normal cannot be determined by measuring
the resistance of the speed sensor with a multimeter.
Damages in the engine
Bkup speed sensor or
9 Perform checks since the engine Bkup speed sensor installation may be defective (loose).
defective installation
(installed loosely)

10 Defective resistance 2. Disconnect connector P1_G_RES, and connect T-adapter to the male side.
Resistance Between P1_G_RES (male) (1) and (2) 620 Ω

2. Disconnect connectors ECM1 J1, P1_G, and P1_G_RES, and connect T-adapter to
each female side.
11 Between ECM1 J1 (female) (78) and P1_G (female) (A) Max. 1 Ω
ness
Resistance Between ECM1 J1 (female) (54) and P1_G (female) (B) Max. 1 Ω
Between ECM1 J1 (female) (18) and P1_G (female) (C) Max. 1 Ω

2. Disconnect connectors ECM1 J1 and P1_G, and connect T-adapter to either female
12
ness
Between ground and ECM1 J1 (female) (18) or P1_G
(female) (C)

2. Disconnect connectors P1_G and P1_G_RES, and connect T-adapter to female side
Hot short circuit in wiring of P1_G.
13
harness 3. Turn the start switch to the ON position
Voltage Between P1_G (female) (C) and ground Max. 1 V

2. Disconnect connectors ECM1 J1, P1_G and P1_G_RES, and connect T-adapter to
female side of ECM1 J1 or P1_G.
14 Between ECM1 J1 (female) (78) and (18), or between
ness Min. 1 MΩ
P1_G (female) (A) and (C)
Resistance
Between ECM1 J1 (female) (54) and (18), or between
Min. 1 MΩ
P1_G (female) (B) and (C)
HD465-8, HD605-8 40-285


If there is no failure with the checks above, the engine Bkup speed sensor may be defec-
tive. (Since this is an internal problem, you cannot troubleshoot.)
REMARK
Defective engine Bkup In normal condition, output from the speed sensor is pulse voltage of 5 V, which can-
15 q
speed sensor not be measured with a multimeter.
Circuit diagram related to Engine NE and Bkup speed sensor
40-286 HD465-8, HD605-8

HD465-8, HD605-8 40-287


Action level Failure code Charge Air Pressure Sensor High Error
Failure
Details of fail-
A high voltage is generated in the signal circuit of the charge air pressure sensor (boost pressure sensor).
ure
q Sets charge air pressure (boost pressure) to set value (400 kPa {4.1 kg/cm2}) for operation.
Action of con- q Closes EGR valve and fully opens VGT.
q Stops regeneration control.
Effect to the q Engine throttle response is unsatisfactory.
machine q Engine power decreases.
q If failure code [CA352] or [CA386] is also shown, the sensor power supply system may be defective.
Troubleshoot for it first.
q Signal voltage from the charge pressure sensor (boost pressure sensor) can be checked by the moni-
toring function. (Code: 36501)
Related infor- q Signal voltage from the charge pressure sensor (boost pressure sensor) can be checked by the moni-
mation toring function. (Code: 36500)
q Deterioration of engine power cancels when you turn the start switch to OFF after this failure code is
deleted. (This deration is not canceled when you only remove the failure code.)

connector

Open circuit in wiring har- 2. Disconnect connectors ECM1 J1 and PIM, and connect T-adapter to each female
2 side.
ness
Resistance Between ECM1 J1 (female) (54) and PIM (female) (2) Max. 1 Ω

2. Disconnect connector PIM, and connect T-adapter to the female side, or disconnect
Hot short circuit in wiring connector PIM, and put T-adapter into connector ECM1 J1.
harness
Between PIM (female) (3) and (2), or between ECM1 J1
Voltage Max. 1 V
(45) and (54)

Short circuit in wiring har- 2. Disconnect connectors ECM1 J1 and PIM, and connect T-adapter to female side of
4 ECM1 J1.
ness
Resistance Between ECM1 J1 (female) (45) and (78) Min. 1 MΩ

2. Put T-adapter into connector ECM1 J1 or PIM.
Defective charge (Boost) 3. Turn the start switch to the ON position
5
pressure sensor
Between ECM1 J1 (45) and (54), or between PIM (3) and
(2)
40-288 HD465-8, HD605-8

Circuit diagram related to charge air pressure sensor
HD465-8, HD605-8 40-289


Action level Failure code Charge Air Pressure Sensor Low Error
Failure
Details of fail-
A low voltage is generated in the signal circuit of the charge air pressure sensor (boost pressure sensor).
ure
q Sets charge air pressure (boost pressure) to set value (400 kPa {4.1 kg/cm2}) for operation.
Action of con- q Closes EGR valve and fully opens VGT.
Effect to the q Engine throttle response is unsatisfactory.
q Signal voltage from the charge pressure sensor (boost pressure sensor) can be checked by the moni-
Related infor- q Signal voltage from the charge pressure sensor (boost pressure sensor) can be checked by the moni-
mation toring function. (Code: 36500)
q Engine power deration is canceled by turning the starting switch to OFF position after this failure code
is cleared. (This deration is not canceled only by clearing the failure code.)

connector

2. Disconnect connectors ECM1 J1 and PIM, and connect T-adapter to each female
side.
2 Between ECM1 J1 (female) (78) and PIM (female) (1) Max. 1 Ω
ness
Resistance Between ECM1 J1 (female) (45) and PIM (female) (3) Max. 1 Ω
Between ECM1 J1 (female) (54) and PIM (female) (2) Max. 1 Ω
1. Examine with the start switch OFF.

2. Disconnect connectors ECM1 J1 and PIM, and connect T-adapter to either female
3
ness
Between ground and ECM1 J1 (female) (45) or PIM
(female) (3)

Short circuit in wiring har- 2. Disconnect connectors ECM1 J1 and PIM, and connect T-adapter to female side of
4 ECM1 J1.
ness
Resistance Between ECM1 J1 (female) (45) and (54) Min. 1 MΩ

2. Put T-adapter into connector ECM1 J1 or PIM.
Defective charge (Boost) 3. Turn the start switch to the ON position
5
pressure sensor
Between ECM1 J1 (45) and (54), or between PIM (3) and
(2)
40-290 HD465-8, HD605-8

Circuit diagram related to charge air pressure sensor
HD465-8, HD605-8 40-291


Action level Failure code Throttle Sensor High Error
Failure
Details of fail-
A high voltage is generated in the throttle sensor signal circuit.
ure
Action of con- Set the throttle position to 0 % with the accelerator pedal OFF, and a set value with the accelerator pedal
troller ON. Run the engine.
Effect to the
Full throttle is not achieved.
machine
q If failure code [CA2185] is shown, the sensor power supply system may be defective. Troubleshooting
for it first.
q Input voltage from the throttle sensor can be checked by the monitoring function. (Code: 03000)
Related infor-
q Accelerator pedal position detected by the throttle sensor can be checked by the monitoring function.
mation
(Code: 31701)
q After the repair is completed, check that the failure code is cleared by the following procedure.

connector

Hot short circuit in wiring 2. Disconnect connector AS1, and connect T-adapter to the female side.
harness
Voltage Between AS1 (female) (2) and ground Max. 1 V

2. Disconnect connectors ECM1 J2 and AS1, and connect T-adapter to either female
Short circuit in wiring har- side.
3
ness
Between ECM1 J2 (female) (9) and (10), or between L01

2. Put T-adapter into connector AS1.
Defective throttle sensor 4. Depress the accelerator pedal, and troubleshoot.
4
(accelerator pedal) Depress the accelerator
3.7 to 4.0 V
pedal.
Voltage Between AS1 (2) and (3)
When you release the accel-
0.5 to 0.8 V
erator pedal
40-292 HD465-8, HD605-8

Circuit diagram related to throttle sensor
HD465-8, HD605-8 40-293


Action level Failure code Throttle Sensor Low Error
Failure
Details of fail-
A low voltage is generated in the throttle sensor signal circuit.
ure
Action of con- Set the throttle position to 0 % with the accelerator pedal OFF and a set value with the accelerator pedal
troller ON, and run the engine.
Effect to the
machine
q If failure code [CA2186] is shown, sensor power supply system may be defective. Troubleshoot for it
first.
Related infor-
mation
(Code: 31701)

connector

2. Disconnect connectors ECM1 J2, AS1, and AS2, and connect T-adapter to each
female side.
Between ECM1 J2 (female) (9) and AS1 (female)
Max. 1 Ω
(1)
Open circuit in wiring har- Max. 1 Ω
2 (2)
ness
Resistance Max. 1 Ω
(3)
Max. 1 Ω
(2)
Max. 1 Ω
(1)

3
ness
Between ground and ECM1 J2 (female) (10) or AS1
(female) (2)

4
ness
Between ECM1 J2 (female) (10) and (33), or
between AS1 (female) (2) and (3)
40-294 HD465-8, HD605-8


2. Put T-adapter into connector AS1.
Defective throttle sensor 4. Depress the accelerator pedal, and troubleshoot.
5
(accelerator pedal) Depress the acceler-
3.7 to 4.0 V
ator pedal.
When you release
0.5 to 0.8 V
the accelerator pedal
HD465-8, HD605-8 40-295


Action level Failure code Engine Oil Pressure Sensor High Error
Failure
Details of fail-
A high voltage is generated in the signal circuit of the engine oil pressure sensor.
ure
Action of con-
troller Sets engine oil pressure to set value (250 kPa {2.5 kg/cm2}) for operation.
Effect to the
None in particular
machine
q Signal voltage from the engine oil pressure sensor can be checked by the monitoring function. (Code:
Related infor- 37201)
mation q Oil pressure detected by the engine oil pressure can be checked by the monitoring function. (Code:
37200)

connector

Open circuit in wiring har- 2. Disconnect connectors ECM1 J1 and POIL, and connect T-adapter to each female
2 side.
ness
Resistance Between ECM1 J1 (female) (54) and POIL (female) (2) Max. 1 Ω

2. Disconnect connector POIL.
3. Connect T-adapter to female side of connector POIL, or put T-adapter into connector
Hot short circuit in wiring ECM1 J1.
3
harness
4. Turn the start switch to the ON position(with connector POIL disconnected).
Between POIL (female) (3) and (2), or between ECM1 J1
Voltage Max. 1 V
(85) and (54)

2. Disconnect connectors ECM1 J1 and POIL, and connect T-adapter to either female
4
ness
POIL (female) (1) and (3)

2. Put T-adapter into connector ECM1 J1 or POIL.
Defective engine oil pres- 3. Turn the start switch to the ON position
5
sure sensor
Between ECM1 J1 (85) and (54), or between POIL (3) and
(2)
40-296 HD465-8, HD605-8

Circuit diagram related to engine oil pressure sensor
HD465-8, HD605-8 40-297


Action level Failure code Engine Oil Pressure Sensor Low Error
Failure
Details of fail-
A low voltage is generated in the signal circuit of the engine oil pressure sensor.
ure
Action of con-
troller Sets engine oil pressure to set value (250 kPa {2.5 kg/cm2}) for operation.
Effect to the
None in particular
machine
q Signal voltage from the engine oil pressure sensor can be checked by the monitoring function. (Code:
mation q Oil pressure detected by the engine oil pressure can be checked by the monitoring function. (Code:
37200)

connector

2. Disconnect connectors ECM1 J1 and POIL, and connect T-adapter to each female
side.
2 Between ECM1 J1 (female) (78) and POIL (female) (1) Max. 1 Ω
ness
Resistance Between ECM1 J1 (female) (54) and POIL (female) (2) Max. 1 Ω
Between ECM1 J1 (female) (85) and POIL (female) (3) Max. 1 Ω
1. Turn the start switch to the OFF position

3
ness
Between ground and ECM1 J1 (female) (85) or POIL
(female) (3)

4
ness
POIL (female) (2) and (3)

2. Put T-adapter into connector ECM1 J1 or POIL.
Defective engine oil pres- 3. Turn the start switch to the ON position
5
sure sensor
Between ECM1 J1 (85) and (54), or between POIL (3) and
(2)
40-298 HD465-8, HD605-8

Circuit diagram related to engine oil pressure sensor
HD465-8, HD605-8 40-299


Action level Failure code Coolant Temperature Sensor High Error
Failure
Details of fail-
A high voltage is generated in the signal circuit of the engine coolant temperature sensor.
ure
Action of con-
Sets coolant temperature to the set value for operation.
troller
Effect to the q Engine is hard to start in low temperature.
machine q Overheat prevention function does not operate.
k Do not examine and replace the coolant temperature sensor when coolant temperature is high.
q Signal voltage from the engine coolant temperature sensor can be checked by the monitoring function.
(Code: 04105)
Related infor- q Temperature detected by the engine coolant temperature sensor can be checked by the monitoring
mation function. (Code: 04107)
q The circuit is configured so that this failure code is displayed, not the one indicating a "Low Error" when
the sensor connector is disconnected.

connector

2. Disconnect connector TWTR, and connect socket to the male side.
REMARK
Regard the coolant temperature sensor as normal if its resistance is 700 Ω to 37 kΩ when
coolant temperature is Min. 0 °C.
0 °C 30 to 37 kΩ
Defective coolant tempera- 9.3 to 10.7
2 25 °C
ture sensor kΩ
Between TWTR (male) (A)
and (B) (Coolant tempera-
50 °C 3.2 to 3.8 kΩ
Resistance ture sensor heat properties)
80 °C 1.0 to 1.3 kΩ
95 °C 700 to 800 Ω
Between TWTR (male) (B)
All range Min. 1 MΩ
and ground

2. Disconnect connectors ECM1 J1 and TWTR, and connect T-adapter to female side of
Open circuit in wiring har- ECM1 J1.
3
ness
Between ECM1 J1 (female) (83) and TWTR (female) (A) Max. 1 Ω
Resistance
Between ECM1 J1 (female) (54) and TWTR (female) (B) Max. 1 Ω

2. Disconnect connector TWTR.
Hot short circuit in wiring 3. Put T-adapter into connector ECM1 J1.
4
harness
Voltage Between ECM1 J1 (83) and (54) Max. 5.25 V
40-300 HD465-8, HD605-8


Short circuit in wiring har- ECM1 J1.
5
ness
Between ECM1 J1 (female) (83) and each pin other than
pin (83)
Circuit diagram related to coolant temperature sensor
HD465-8, HD605-8 40-301


Action level Failure code Coolant Temperature Sensor Low Error
Failure
Details of fail-
A low voltage is generated in the signal circuit of the engine coolant temperature sensor.
ure
Action of con-
Sets coolant temperature to the set value for operation.
troller
machine q Overheat prevention function does not operate.
k Do examine and replace the coolant temperature sensor when coolant temperature is high.
q Signal voltage from the engine coolant temperature sensor can be checked by the monitoring function.
Related infor- (Code: 04105)
mation q Temperature detected by the engine coolant temperature sensor can be checked by the monitoring
function. (Code: 04107)

connector

2. Disconnect connector TWTR, and connect socket to the male side.
REMARK
Regard the coolant temperature sensor as normal if its resistance is 700 Ω to 37 kΩ when
coolant temperature is Min. 0 °C.
0 °C 30 to 37 kΩ
Defective coolant tempera- 9.3 to 10.7
2 25 °C
ture sensor kΩ
Between TWTR (male) (A)
and (B) (Coolant tempera-
50 °C 3.2 to 3.8 kΩ
Resistance ture sensor heat properties)
80 °C 1.0 to 1.3 kΩ
95 °C 700 to 800 Ω
Between TWTR (male) (B)
and ground

Ground fault in wiring har- 2. Disconnect connectors ECM1 J1 and TWTR, and connect T-adapter to female side of
3 ECM1 J1.
ness
Resistance Between ECM1 J1 (female) (83) and ground Min. 1 MΩ

4
ness
pin (83)
40-302 HD465-8, HD605-8

Circuit diagram related to coolant temperature sensor
HD465-8, HD605-8 40-303


Action level Failure code Charge Air Temperature Sensor High Error
Failure
Details of fail-
A high voltage is generated in the signal circuit of the charge (boost) temperature sensor.
ure
q Sets charge temperature (boost temperature) to set value (70 °C) for operation.
Action of con- q Closes EGR valve.
k Do not examine and replace the coolant temperature sensor when the coolant temperature is
high.
q Signal voltage from the charge temperature (boost pressure sensor) can be checked by the monitoring
Related infor- q Temperature detected by the charge temperature sensor (boost temperature sensor) can be checked
mation by the monitoring function. (Code: 18500)

connector

2. Disconnect connector TIM, and connect socket to the male side.
REMARK
Regard the charge temperature sensor as normal if its resistance is 280 Ω to 382 kΩ.
291 to 382
-40 °C
kΩ
-20 °C 85 to 109 kΩ
Defective charge tempera-
2
ture sensor Between TIM (male) (A) and 0 °C 29 to 36 kΩ
(B) (Charge temperature
30 °C 7.3 to 8.8 kΩ
Resistance heat properties)
60 °C 2.3 to 2.7 kΩ
90 °C 860 to 970 Ω
130 °C 280 to 320 Ω
Between TIM (male) (B) and
ground

Open circuit in wiring har- 2. Disconnect connector ECM1 J1, and connect T-adapter to the female side.
3
ness Between ECM1 J1 (female)
Resistance 280 Ω to 382 kΩ
(62) and (54)
40-304 HD465-8, HD605-8


2. Disconnect connector TIM.
4
harness
Between ECM1 J1 (62) and
Voltage Max. 5.25 V
(54)

2. Disconnect connectors ECM1 J1 and TIM, and connect T-adapter to female side of
5
ness Between ECM1 J1 (female)
Resistance (62) and each pin other than Min. 1 MΩ
pin (62)
Circuit diagram related to charge temperature sensor
HD465-8, HD605-8 40-305


Action level Failure code Charge Air Temperature Sensor Low Error
Failure
Details of fail-
A low voltage is generated in the signal circuit of the charge (boost) temperature sensor.
ure
q Sets charge temperature (boost temperature) to set value (70 °C) for operation.
q Signal voltage from the charge temperature (boost pressure sensor) can be checked by the monitoring
q Temperature detected by the charge temperature sensor (boost temperature sensor) can be checked
Related infor- by the monitoring function. (Code: 18500)
mation q Deterioration of engine power cancels when you turn the start switch to OFF after this failure code is
deleted.

connector

2. Disconnect connector TIM, and connect socket to the male side.
REMARK
Regard the charge temperature sensor as normal if its resistance is 280 Ω to 382 kΩ.
291 to 382
-40 °C
kΩ
-20 °C 85 to 109 kΩ
Defective charge tempera-
2
ture sensor Between TIM (male) (A) and 0 °C 29 to 36 kΩ
(B) (Charge temperature
30 °C 7.3 to 8.8 kΩ
Resistance heat properties)
60 °C 2.3 to 2.7 kΩ
90 °C 860 to 970 Ω
130 °C 280 to 320 Ω
Between TIM (male) (B) and
ground

Ground fault in wiring har- 2. Disconnect connector ECM1 J1, and connect T-adapter to the female side.
3
ness

2. Disconnect connectors ECM1 J1 and TIM, and connect T-adapter to female side of
4
ness
pin (62)
40-306 HD465-8, HD605-8


Circuit diagram related to charge temperature sensor
HD465-8, HD605-8 40-307


Action level Failure code Sensor 2 Supply Voltage Low Error
Failure
Details of fail-
A high voltage is generated in the sensor 2 power supply (5 V) circuit.
ure
q Ignores signals from the EGR valve lift sensor and VGT position sensor. Sets values before it senses
an error for operation.
Action of con-
q Ignores signal from the doser fuel pressure sensor, and sets values before it senses an error for oper-
troller
ation.
q Derates the engine power for operation.
Effect to the
Engine power decreases.
machine
Related infor- is cleared. (This deration is not canceled only by clearing the failure code.)

connector

2. Disconnect these connectors one by one, and turn the start switch to the ON position
each time.
3. If this failure code is not shown, the disconnected device is defective. Repeat steps 1
to 3 until you make sure that defective devices which caused the failure are no longer
found.
REMARK
Defective sensor or wiring Since the connector is disconnected, other failure codes appear. Ignore all of the shown
2
harness failure codes other than this one.
AFT1_PFUE
Dosing fuel pressure sensor
L
Connector EGR valve lift sensor SEGR

VGT position sensor SVGT
Engine wiring harness ECM1 J1
40-308 HD465-8, HD605-8

Circuit diagram related to sensor 2 power supply circuit
HD465-8, HD605-8 40-309


Action level Failure code Engine Oil Temperature Sensor High Error
Failure
Details of fail-
A high voltage is generated in the signal circuit of the engine oil temperature sensor.
ure
Action of con-
Sets oil temperature to set value (100 °C) for operation.
troller
Effect to the
None in particular
machine
q Signal voltage from the engine oil temperature sensor can be checked by the monitoring function.
(Code: 42702)
q Temperature detected by the engine oil temperature sensor can be checked by the monitoring function.
mation q The circuit is configured so that this failure code is displayed, not the one indicating a "Low Error" when

connector

2. Disconnect connector TOIL, and connect socket to the male side.
REMARK
Regard the oil temperature sensor as normal if its resistance is 725 Ω to 37 kΩ when oil
temperature is Min. 0 °C.
0 °C 30 to 37 kΩ
Defective oil temperature 9.3 to 10.7
2 25 °C
sensor kΩ
Between TOIL (male) (A)
and (B) (Oil temperature
50 °C 3.2 to 3.8 kΩ
Resistance sensor heat properties)
80 °C 1.0 to 1.3 kΩ
95 °C 725 to 756 Ω
Between TOIL (male) (B)
and ground

2. Disconnect connectors ECM1 J1 and TOIL, and connect T-adapter to female side of
Open circuit in wiring har- ECM1 J1.
3
ness
Between ECM1 J1 (female) (90) and TOIL (female) (A) Max. 1 Ω
Resistance
Between ECM1 J1 (female) (54) and TOIL (female) (B) Max. 1 Ω

2. Disconnect connector TOIL.
4
harness
Voltage Between ECM1 J1 (90) and (54) Max. 5.25 V
40-310 HD465-8, HD605-8


5
ness
pin (90)
Circuit diagram related to engine oil temperature sensor
HD465-8, HD605-8 40-311


Action level Failure code Engine Oil Temperature Sensor Low Error
Failure
Details of fail-
A low voltage is generated in the signal circuit of the engine oil temperature sensor.
ure
Action of con-
Sets oil temperature to set value (100 °C) for operation.
troller
Effect to the
None in particular
machine
q Signal voltage from the engine oil temperature sensor can be checked by the monitoring function.
(Code: 42702)
Related infor- q Temperature detected by the engine oil temperature sensor can be checked by the monitoring function.
mation (Code: 42700)

connector

2. Disconnect connector TOIL, and connect socket to the male side.
REMARK
Regard the oil temperature sensor as normal if its resistance is 725 Ω to 37 kΩ when oil
temperature is Min. 0 °C.
0 °C 30 to 37 kΩ
Defective oil temperature 9.3 to 10.7
2 25 °C
sensor kΩ
Between TOIL (male) (A)
and (B) (Oil temperature
50 °C 3.2 to 3.8 kΩ
Resistance sensor heat properties)
80 °C 1.0 to 1.3 kΩ
95 °C 725 to 756 Ω
Between TOIL (male) (B)
and ground

Ground fault in wiring har- 2. Disconnect connectors ECM1 J1 and TOIL, and connect T-adapter to female side of
3 ECM1 J1.
ness

4
ness
pin (90)
40-312 HD465-8, HD605-8

Circuit diagram related to engine oil temperature sensor
HD465-8, HD605-8 40-313


Action level Failure code Ambient Pressure Sensor High Error
Failure
Details of fail-
A high voltage is generated in the signal circuit of the ambient pressure sensor.
ure
q Sets ambient pressure to set value (52.44 kPa {0.53 kg/cm2}) for operation.
Effect to the
machine
q Signal voltage from the ambient pressure sensor can be checked by the monitoring function. (Code:
37401)
Related infor- q Ambient pressure detected by the ambient pressure sensor can be checked by the monitoring function.

connector

Open circuit in wiring har- 2. Disconnect connectors ECM1 J1 and PAMB, and connect T-adapter to each female
2 side.
ness
Resistance Between ECM1 J1 (female) (54) and PAMB (female) (2) Max. 1 Ω

Hot short circuit in wiring 2. Disconnect connector PAMB, and connect T-adapter to the female side.
harness
Voltage Between PAMB (female) (3) and (2) Max. 1 V

2. Disconnect connectors ECM1 J1 and PAMB, and connect T-adapter to either female
4
ness
PAMB (female) (1) and (3)

2. Put T-adapter into connector ECM1 J1 or PAMB.
Defective ambient pres- 3. Turn the start switch to the ON position
5
sure sensor
Between ECM1 J1 (44) and (54), or between PAMB (3)
and (2)
40-314 HD465-8, HD605-8

Circuit diagram related to the ambient pressure sensor
HD465-8, HD605-8 40-315


Action level Failure code Ambient Pressure Sensor Low Error
Failure
Details of fail-
A low voltage is generated in the signal circuit of the ambient pressure sensor.
ure
q Sets ambient pressure to set value (52.44 kPa {0.53 kg/cm2}) for operation.
Effect to the
machine
q Signal voltage from the ambient pressure sensor can be checked by the monitoring function. (Code:
37401)
Related infor- q Ambient pressure detected by the ambient pressure sensor can be checked by the monitoring function.

connector

2. Disconnect connectors ECM1 J1 and PAMB, and connect T-adapter to each female
side.
2 Between ECM1 J1 (female) (44) and PAMB (female) (3) Max. 1 Ω
ness
Resistance Between ECM1 J1 (female) (54) and PAMB (female) (2) Max. 1 Ω
Between ECM1 J1 (female) (78) and PAMB (female) (1) Max. 1 Ω

3
ness
Between ground and ECM1 J1 (female) (44) or PAMB
(female) (3)

4
ness
PAMB (female) (2) and (3)

2. Put T-adapter into connector ECM1 J1 or PAMB.
Defective ambient pres- 3. Turn the start switch to the ON position
5
sure sensor
Between ECM1 J1 (44) and (54), or between PAMB (3)
and (2)
40-316 HD465-8, HD605-8


Circuit diagram related to ambient pressure sensor
HD465-8, HD605-8 40-317


Action level Failure code Sensor 2 Supply Voltage High Error
Failure
Details of fail-
A high voltage is generated in the sensor 2 power supply (5 V) circuit.
ure
q Ignores signals from the EGR valve lift sensor and VGT position sensor. Sets values before it senses
an error for operation.
Action of con-
q Ignores signal from the doser fuel pressure sensor, and sets values before it senses an error for oper-
troller
ation.
Effect to the
machine

connector

each time.
found.
REMARK
Defective sensor or wiring Since the connector is disconnected, other failure codes appear. Ignore all of the shown
2
harness failure codes other than this one.
AFT1_PFUE
L
Connector EGR valve lift sensor SEGR

VGT position sensor SVGT
40-318 HD465-8, HD605-8

HD465-8, HD605-8 40-319


Action level Failure code Engine Overspeed
Failure
Details of fail-
Engine speed exceeds operation range.
ure
Action of con-
Restricts fuel injected rate until speed is lowered to operation range.
troller
Effect to the
Engine speed varies.
machine
q If another failure code is also shown at the same time, troubleshoot for it first.
Related infor- q Engine speed can be checked by the monitoring function. (Code: 01002)
Procedure: Start the engine and run at high idle speed.

The fuel used is not the
1 Fuel used may not be appropriate. Ask the operator.
fuel specified
2 Incorrect machine usage The machine is not operated correctly, instruct on proper operation.
40-320 HD465-8, HD605-8


Action level Failure code NE Speed Sensor Supply Voltage Error
Failure
Details of fail-
Error occurs in the NE speed sensor power supply (5 V) circuit.
ure
Action of con-
Controls by Bkup speed sensor signal.
troller
Effect to the q Engine stops (when Bkup speed sensor is also defective).
machine q When the engine is stopped, the engine will not start (when the Bkup speed sensor is also defective.)

connector

each time.
Defective sensor or wiring found.
2
harness REMARK
Since the connector is disconnected, other failure codes appear. Ignore all of the shown
failure codes other than this one.
NE speed sensor NE
Connector
Circuit diagram related to NE speed sensor
HD465-8, HD605-8 40-321


Action level Failure code NE Speed Sensor Supply Voltage High Error
Failure
Details of fail-
A high voltage is generated in the NE speed sensor power supply (5 V) circuit.
ure
Action of con-
Controls by Bkup speed sensor signal.
troller
Effect to the q Engine stops (when Bkup speed sensor is also defective).
machine q When the engine is stopped, the engine will not start (when the Bkup speed sensor is also defective.)

connector

each time.
2
harness REMARK
Since the connector is disconnected, other failure codes appear. Ignore all of the shown
failure codes other than this one.
NE speed sensor NE
Connector
Circuit diagram related to the NE speed sensor
40-322 HD465-8, HD605-8


Action level Failure code PCV 1 Short Circuit Error
Failure
Details of fail-
Short circuit is found in the supply pump PCV1 circuit.
ure
Action of con-
Stops driving PCV1.
troller
machine q Engine is hard to start
q When the engine is running normally, pulse voltage of approximately 24 V is provided to P1_PCV1 (1).
Related infor- Pulse voltage cannot be measured with a multimeter.
mation q After the repair is completed, check that the failure code is cleared by the following procedure.

connector

2. Disconnect connector P1_PCV1, and connect socket to the male side.
Defective supply pump
2
P1_PCV1 Between P1_PCV1 (male) (1) and (2) 2.3 to 5.3 Ω
Resistance
Between P1_PCV1 (male) (1) and ground Min. 1 MΩ

2. Disconnect connectors ECM1 J1 and P1_PCV1, and connect T-adapter to each
Ground fault in wiring har- female side.
3
ness
Between ECM1 J1 (female) (23) and ground Min. 1 MΩ
Resistance

harness
Voltage Between ECM1 J1 (24) and ground Max. 1 V

Short circuit in wiring har- 2. Disconnect connector ECM1 J1, and connect T-adapter to the female side.
5
ness Between ECM1 J1 (female) (23) and (24) (P1_PCV1 resis-
Resistance 2.3 to 5.3 Ω
tor)
HD465-8, HD605-8 40-323

Circuit diagram related to fuel supply pump PCV 1
40-324 HD465-8, HD605-8


Action level Failure code PCV 1 Open Circuit Error
Failure
Details of fail-
Open circuit is found in the supply pump P1_PCV1 circuit.
ure
Action of con-
None in particular
troller

connector

2
Resistance

3
tor)
HD465-8, HD605-8 40-325


Action level Failure code PCV 2 Short Circuit Error
Failure
Details of fail-
Short circuit is found in the supply pump P1_PCV2 circuit.
ure
Action of con-
Stops operation of P1_PCV2.
troller

connector

2
Resistance

3
ness
Resistance

harness

Short circuit in wiring har- 2. Disconnect connector ECM1 J1, and connect T-adapter to the female side.
5
tor)
40-326 HD465-8, HD605-8

HD465-8, HD605-8 40-327


Action level Failure code PCV 2 Open Circuit Error
Failure
Details of fail-
Open circuit is found in the supply pump P1_PCV2 circuit.
ure
Action of con-
None in particular
troller

connector

2
Resistance

3
tor)
40-328 HD465-8, HD605-8


Action level Failure code Injector #1 (L#1) Open Circuit Error or Short Circuit Error
Failure
Details of fail-
Injector #1 circuit has open circuit or short circuit.
ure
Action of con-
None in particular
troller
machine q Engine is not constant.
q When the engine is running normally, a pulse voltage of approximately 65 V is provided to the injector
Related infor- (+) side, but it cannot be measured with a multimeter.

connector

2. Disconnect connector CN1, and connect T-adapter to the male side.
2 Defective injector #1
Between CN1 (male) (1) and (2) 0.4 to 1.1 Ω
Resistance
Between CN1 (male) (1) and ground Min. 1 MΩ

2. Disconnect connectors ECM1 J1 and CN1, and connect T-adapter to each female
Open circuit in wiring har- side.
3
ness
Between ECM1 J1 (female) (25) and CN1 (female) (1) Max. 1 Ω
Resistance

side.
Ground fault in wiring har-
4 Between ground and ECM1 J1 (female) (25) or CN1
ness Min. 1 MΩ
(female) (1)
Resistance
Between ground and ECM1 J1 (female) (1) or CN1
Min. 1 MΩ
(female) (2)

2. Put T-adapter into connector ECM1 J1.
Hot short circuit in wiring
5 REMARK
harness
If the ground fault or hot short circuit is found, the failure codes [CA322], [CA331], and
[CA324] are shown at the same time.
HD465-8, HD605-8 40-329


2. Disconnect connector ECM1 J1, and connect T-adapter to the female side.
Short circuit in wiring har- Between ECM1 J1 (female) (25) and each pin other than
6 No continuity
ness pin (25)
Continuity
Between ECM1 J1 (female) (1) and each pin other than pin
No continuity
(1)
Defective other cylinder If the failure code for problems of more than one injector is shown, troubleshoot for this
7
injectors or wiring harness failure code first.
Circuit diagram related to injector #1
40-330 HD465-8, HD605-8


Failure
Details of fail-
ure
Action of con-
None in particular
troller

connector

Resistance

3
ness
Resistance

side.
ness Min. 1 MΩ
(female) (1)
Resistance
Min. 1 MΩ
(female) (2)

2. Put T-adapter into connector ECM1 J1.
5 REMARK
harness
If a ground fault or hot short circuit is found, the failure codes [CA323], [CA325], and
HD465-8, HD605-8 40-331


2. Disconnect connector ECM1 J1, and connect T-adapter to the female side.
Short circuit in wiring har- Between ECM1 J1 (female) (50) and each pin other than
6 No continuity
ness pin (50)
Continuity
No continuity
pin (74)
Defective other cylinder If the failure code for problems of more than one injector is shown, troubleshoot for this
7
injectors or wiring harness failure code first.
40-332 HD465-8, HD605-8


Failure
Details of fail-
ure
Function of
None in particular
Controller
Effect on the q Engine power decreases.
No. Cause Procedure, test location, specifications and remarks

defective, disconnected, or loosened due to heat and vibration. See descriptions of wir-
1 ing harnesses and connectors in the table "Electrical equipment" in "CHECKS BEFORE
connector
1. Turn the starting switch to the OFF position.

2. Disconnect connector CN3, and connect T adapter to the male side.
Resistance

2. Disconnect connectors ECM1 J1 and CN3, and connect T adapter to each female
3
ness
Resistance

side.
ness Min. 1 MΩ
(female) (1)
Resistance
Min. 1 MΩ
(female) (2)

2. Insert T adapter into connector ECM1 J1.
3. Turn the start switch to the ON position.
5 REMARK
harness
If a ground error or hot short circuit is sensed, the failure codes [CA322], [CA331], and
HD465-8, HD605-8 40-333


2. Disconnect connector ECM1 J1, and connect T adapter to the female side.
Short circuit in wiring har- Between ECM1_J1 (female) (27) and each pin other than
6 No continuity
ness pin (27)
Continuity
Between ECM1_J1 (female) (3) and each pin other than
No continuity
pin (3)
Defective other cylinder If the failure code for more than one injector is shown, troubleshoot for this failure code
7
injectors or wiring harness first.
If there is no failure found by these checks, the engine controller is defective. (Since this
is an internal failure, you cannot troubleshoot.)
40-334 HD465-8, HD605-8


Failure
Details of fail-
ure
Function of
None in particular
Controller

connector

Resistance

3
ness
Resistance

side.
ness Min. 1 MΩ
(female) (1)
Resistance
Min. 1 MΩ
(female) (2)

5 REMARK
harness
HD465-8, HD605-8 40-335


6 No continuity
ness pin (51)
Continuity
No continuity
pin (75)
7
40-336 HD465-8, HD605-8


Failure
Details of fail-
ure
Function of
None in particular
Controller

connector

Resistance

3
ness
Resistance

side.
ness Min. 1 MΩ
(female) (1)
Resistance
Min. 1 MΩ
(female) (2)

5 REMARK
harness
HD465-8, HD605-8 40-337


6 No continuity
ness pin (26)
Continuity
No continuity
pin (2)
7
40-338 HD465-8, HD605-8


Failure
Details of fail-
ure
Function of
None in particular
Controller

connector

Resistance

3
ness
Resistance

side.
ness Min. 1 MΩ
(female) (1)
Resistance
Min. 1 MΩ
(female) (2)

5 REMARK
harness
If ground fault or hot short circuit is detected, the failure codes [CA323], [CA325], and
[CA332] are displayed at the same time.
HD465-8, HD605-8 40-339


6 No continuity
ness pin (49)
Continuity
No continuity
pin (73)
7
40-340 HD465-8, HD605-8


Action level Failure code Engine Controller Internal Abnormality
Failure
Details of fail-
Internal failure is sensed in the engine controller.
ure
Function of
None in particular
Controller
Effect on the Engine operates correctly, however, the engine may stop during operation or is not able to start after it is
machine stopped.
q Power supply voltage of the engine controller can be checked by the monitoring function. (Code: 03203)
Related infor-
mation
Procedure: Turn the start switch to the ON position.

connector
Check battery voltage and specific gravity of battery electrolyte.
Battery voltage (per 1 cell) Min. 12 V
2 Defective battery
Battery voltage (2 cells in-line) Min. 24 V
Specific gravity of battery electrolyte Min. 1.26

3 Defective alternator
Between E01 terminal and Engine rotation: Middle 26.0 to 30.5
Voltage
ground range or higher V
HD465-8, HD605-8 40-341

Circuit diagram related to engine controller power supply
40-342 HD465-8, HD605-8

HD465-8, HD605-8 40-343


Action level Failure code Injectors Drive Circuit Error
Failure
Details of fail-
Error is sensed in the injector operation circuit.
ure
Function of
Derates the engine power for operation. (Restricts common rail pressure.)
Controller
Effect on the
machine
q If other failure code (for injector system) is shown at the same time, troubleshoot for it first.
Related infor- q Power supply voltage of the engine controller can be checked by the monitoring function. (Code: 03203)

connector
2 Defective battery

Voltage
40-344 HD465-8, HD605-8

HD465-8, HD605-8 40-345

40-346 HD465-8, HD605-8


Failure
Details of fail-
Low voltage is generated in sensor 1 power supply (5 V) circuit.
ure
q Ignores signal from Bkup speed sensor, and operates by NE speed sensor signal.
q Ignores the signal from the engine oil temperature sensor, and the engine controller sets the oil pressure
to a set value for operation. (250 kPa {2.5 kg/cm2})
q Ignores signal from the ambient pressure sensor, and the engine controller sets the ambient pressure
to a set value for operation. (52.44 kPa {0.53 kg/cm2})
Function of q Ignores signal from the boost pressure sensor, and the engine controller sets the boost pressure to a
Controller set value for operation. (400 kPa {4.1 kg/cm2})
q Ignores signal from the crankcase pressure sensor, and the engine controller sets the crankcase pres-
sure to a set value for operation. (0 kPa {0 kg/cm2})
q Closes EGR valve and fully opens VGT.
Effect on the
machine
q After this failure code is removed, turn the start switch to OFF to cancel the engine power derate. (Re-
Related infor- moval of the failure code does not cancel the derate.)
mation q After the repair is completed, use this procedure to remove the failure code.
Procedure: Turn the starting switch to the ON position.

connector

2. Disconnect the connectors that follow, one by one, and turn the start switch to the ON
position each time.
to 3 to make sure that the defective devices that caused the failure are no longer
found.
REMARK
Defective sensor or wiring Ignore other failure codes caused when you disconnected the connector.
2
harness Bkup speed sensor P1_G
Oil pressure sensor POIL
Charge (Boost) pressure sensor PIM
Connector
Ambient pressure sensor PAMB
Crankcase pressure sensor PCCV
HD465-8, HD605-8 40-347

40-348 HD465-8, HD605-8


Action level Failure code MAF Sensor High Error
Failure
Details of fail-
High frequency input error occurs in signal circuit of mass air flow sensor.
ure
q Sets mass air flow to a specified value (10 kg/min.) or operation.
Function of q Closes EGR valve.
Controller q Derates the engine power for operation.
Phenomenon
on machine
q If failure code [CA3419] or [CA3421] is shown, troubleshoot for it first.
q Sensor output is pulse waveform of approximately 5 V, which cannot be measured with a multimeter.
Related infor- q Engine power deration is canceled by turning the starting switch to OFF position after this failure code
mation is cleared. (This deration is not canceled only by clearing the failure code.)
q After the repair is completed, use this procedure to remove the failure code.

connector

2. Disconnect connector MAF.
Defective mass air flow 3. Turn the start switch to the ON position.
2
and temperature sensor
If this failure code changes from [CA356] to [CA357], mass air flow and temperature sen-
sor are defective.

Open circuit in wiring har- 2. Disconnect connectors ECM1 J1 and MAF, and connect T adapter to each female
3 side.
ness
Resistance Between ECM1 J1 (female) (56) and MAF (female) (3) Max. 1 Ω

2. Disconnect connectors ECM1 J1 and MAF, and connect T adapter to the female side
Short circuit in wiring har- of ECM1 J1.
4
ness
pin (32)
HD465-8, HD605-8 40-349

Circuit diagram related to intake air temperature sensor
40-350 HD465-8, HD605-8


Action level Failure code MAF Sensor Low Error
Failure
Details of fail-
Low frequency input error occurs in signal circuit of mass air flow sensor.
ure
q Sets mass air flow to fixed value (10 kg/min.) or operation.
Effect on the
machine
q When the sensor connector is disconnected, this failure code and [CA691] are shown at the same time.
q Sensor output is pulse waveform of approximately 5 V, which cannot be measured with a multimeter.
Related infor-
mation

connector

Defective mass air flow 2. Replace the Mass air flow sensor
2 3. Turn the starting switch to the ON position.
sensor (internal defect)
If this failure code is not displayed, the original mass air flow sensor is defective.

2. Disconnect connectors ECM1 J1 and MAF, and connect T adapter to each female
side.
3 Between ECM1 J1 (female) (80) and MAF (female) (2) Max. 1 Ω
ness
Resistance Between ECM1 J1 (female) (56) and MAF (female) (3) Max. 1 Ω
Between ECM1 J1 (female) (32) and MAF (female) (1) Max. 1 Ω

2. Disconnect connectors ECM1 J1 and MAF, and connect T adapter to either female
4
ness
Between ground and ECM1 J1 (female) (32) or MAF
(female) (1)

2. Disconnect connector MAF, and connect T adapter to the female side.
Hot short circuit in wiring 3. Turn the start switch to the ON position.
5
harness Ignore the failure code shown on the screen.
Voltage Between MAF (female) (1) and (3) Max. 1 V
HD465-8, HD605-8 40-351


6
ness
pin (32)
40-352 HD465-8, HD605-8


Failure
Details of fail-
High voltage is generated in sensor 1 power supply (5 V) circuit.
ure
q Ignores signal from the Bkup speed sensor, and operates by NE speed sensor signal.
q Ignores signal from the engine oil temperature sensor, and the engine controller sets the oil pressure to
a specified value for operation. (250 kPa {2.5 kg/cm2}).
q Ignores signal from the ambient pressure sensor, and the engine controller sets the ambient pressure
to a specified value for operation. (52.44 kPa {0.53 kg/cm2}).
Function of q Ignores signal from the charge (boost) pressure sensor, and the engine controller sets the charge
Controller (boost) pressure to a specified value for operation.(400 kPa {4.1 kg/cm2}).
q Ignores signal from the crankcase pressure sensor, and the engine controller sets the crankcase pres-
sure to a specified value for operation. (0 kPa {0 kg/cm2}).
Effect on the
machine

connector

position each time.
found.
REMARK
Defective sensor or wiring Ignore other failure codes caused when you disconnected the connector.
2
harness Bkup speed sensor P1_G
Oil pressure sensor POIL
Charge (Boost) pressure sensor PIM
Connector
Ambient pressure sensor PAMB
Crankcase pressure sensor PCCV
HD465-8, HD605-8 40-353

40-354 HD465-8, HD605-8


Action level Failure code Idle Validation SW Error
Failure
Details of fail-
Error occurs in idle validation switch signals 1 and 2 (IVS1 and IVS2).
ure
Function of
Runs the engine using the throttle position sensed by the throttle sensor.
Controller
Effect on the
None in particular
machine
q Input state (ON/OFF) of the idle validation signal 1 can be checked by the monitoring function. (Code:
18300)
Related infor- q Input state (ON/OFF) of the idle validation signal 2 can be checked by the monitoring function. (Code:
mation 18301)

connector

2. Insert T-adapter into connector AS2.
2 Defective Fuel system 3. Turn the starting switch to the ON position.
4.75 to 5.25
V

2. Disconnect connectors ECM1 J2, AS1, and AS2, and connect T adapter to each
female side.
Between ECM1 J2 (female) (62) and AS1 (female) (4) Max. 1 Ω
3 Between ECM1 J2 (female) (44) and AS1 (female) (5) Max. 1 Ω
ness
Resistance Between ECM1 J2 (female) (43) and AS1 (female) (6) Max. 1 Ω

2. Disconnect connectors ECM1 J2 and AS1, and connect T adapter to the female side
of ECM1 J2.
4 Between ECM1_J2 (female) (44) and each pin other than
ness Min. 1 MΩ
pin (44)
Resistance
Min. 1 MΩ
pin (43)
HD465-8, HD605-8 40-355


4. Depress the accelerator pedal, then troubleshoot.
See IVS1 of
Defective accelerator Between AS1 (5) and (4)
5 Fig. 1
pedal
See IVS2 of
Between AS1 (6) and (4)
Voltage Fig. 1
See output
Between AS1 (2) and (3) voltage of
Fig. 1
40-356 HD465-8, HD605-8

Fig. 1
Pedal stroke: Stroke of the accelerator pedal

Output voltage: 2 pin of connector AS1, 10 pin of connector ECM1 J2
IVS1: Signal voltage of the idle validation switch 1
Switch gap: Range where the signals of IVS1 and IVS2 are off at the same time
HD465-8, HD605-8 40-357


Action level Failure code Idle Validation Process Error
Failure
Details of fail-
Idle validation switch signal does not match with the signal of throttle sensor (it is opposite).
ure
q If the idle validation switch signal indicates the accelerator pedal is released, and if the throttle sensor signal
indicates the accelerator pedal is depressed: The throttle position is set to 0% while the idle validation sig-
nal indicates the accelerator pedal is released. The throttle position is set to a specified value when the
Function of
signal indicates the accelerator pedal is depressed.
Controller
q If the idle validation switch signal indicates the accelerator pedal is depressed, and if the throttle sensor
signal indicates the accelerator pedal is released: The throttle position is set to 0 % (engine speed is set
at low idle speed).
Effect on the
Engine speed does not increase from low idle speed.
machine
18300)
18301)
Related infor-
mation
(Code: 31701)

connector

2. Disconnect the connectors AS2 and AS1, and insert T adapters into each female side.
3. Turn the starting switch to the ON position.
2 Defective Fuel system 4.75 to 5.25
V
Voltage
4.75 to 5.25
V
1. Turn the start switch to the OFF position, and turn the battery disconnect switch to the
OFF position.
2. Disconnect connectors ECM1 J2, AS1, and AS2, and connect T adapter to each
female side.
3 Between ECM1 J2 (female) (33) and AS1 (female) (3) Max. 1 Ω
ness
Resistance
40-358 HD465-8, HD605-8

1. Turn the start switch to the OFF position, and turn the battery disconnect switch to the
OFF position.
of ECM1 J2.
4 Min. 1 MΩ
ness pin (44)
pin (43)
Min. 1 MΩ
pin (10)

4. Depress the accelerator pedal, then troubleshoot.
See IVS1 of
Defective accelerator Between AS1 (5) and (4)
5 Fig. 1
pedal
See IVS2 of
Voltage Fig. 1
See output
Between AS1 (2) and (3) voltage of
Fig. 1
HD465-8, HD605-8 40-359

Fig. 1
Pedal stroke: Stroke of the accelerator pedal

Output voltage: 2 pin of connector AS1, 10 pin of connector ECM1 J2
Switch gap: Range where the signals of IVS1 and IVS2 are off at the same time
40-360 HD465-8, HD605-8


Action level Failure code Battery Voltage Low Error
Failure
Details of fail-
Low voltage is generated in the engine controller power supply circuit.
ure
Function of
Operates the engine with power supply voltage at a specified value approximately 6.0 V.
Controller
machine stopped.
Related infor-
mation

connector
2 Defective battery

Voltage
HD465-8, HD605-8 40-361

40-362 HD465-8, HD605-8

HD465-8, HD605-8 40-363


Action level Failure code Battery Voltage High Error
Failure
Details of fail-
High voltage (Min. 36 V) is generated in the engine controller power supply circuit.
ure
Function of
Operates the engine with power supply voltage at a specified value approximately 36 V.
Controller
machine stopped.
Related infor-
mation

connector
2 Defective battery
Turn the start switch to the OFF position.
Start the engine.
Voltage
40-364 HD465-8, HD605-8

HD465-8, HD605-8 40-365

40-366 HD465-8, HD605-8


Action level Failure code Common Rail Pressure High Error 2
Failure
Details of fail-
High pressure error (exceed the maximum setting level) is sensed in the common rail pressure
ure
Function of q Derates the engine power for operation.
Controller q Restricts common rail pressure.
Effect on the
machine
q If failure code [CA451] or [CA452] is shown, the common rail pressure sensor may have an electrical
failure. Troubleshoot for it first.
q Signal voltage from the common rail pressure sensor can be checked by the monitoring function. (Code:
mation q Common rail pressure detected by the common rail pressure sensor can be checked by the monitoring

Fuel used may be out of
1 Fuel used may not be in specification. Speak with operator.
specification
Defective mechanical sys-
2 tem of common rail pres- Common rail pressure sensor may be mechanically defective.
sure sensor
3 Defective overflow valve Inspect the overflow valve for spring damage, seat wear, or a stuck ball.
4 Obstructed overflow piping Inspect the overflow piping. It may be defective.
5 Defective pressure limiter Pressure limiter may be mechanically defective.
HD465-8, HD605-8 40-367


Action level Failure code Common Rail Pressure Sensor High Error
Failure
Details of fail-
High pressure error is sensed in the circuit of the common rail pressure sensor.
ure
Effect on the
machine
36401)
q Common rail pressure detected by the common rail pressure sensor can be checked by the monitoring
Related infor-
mation

connector

2. Disconnect connectors PFUEL and ECM1 J1, and connect T adapter to each female
side.
Open circuit in wiring har- Between ECM1 J1 (female) (82) and PFUEL (female) (1) Max. 1 Ω
2
ness
Between ECM1 J1 (female) (58) and PFUEL (female) (3) Max. 1 Ω
Resistance
Between ECM1 J1 (female) (87) and PFUEL (female) (2)
Max. 1 Ω
(sensor output)

2. Disconnect connector PFUEL.
3. Connect T adapter to female side of connector POIL, or insert T adapter to connector
Hot short circuit in wiring ECM1 J1.
3
harness
Between PFUEL (female) (2) and (3), or between ECM1
Voltage Approx. 5 V
J1 (87) and (58)

2. Disconnect connectors PFUEL and ECM1 J1, and connect T adapter to either female
4
ness
Between PFUEL (female) (2) and (1), or between ECM1
J1 (female) (82) and (87)

2. Insert T adapter into connector PFUEL or ECM1 J1.
Defective common rail 3. Turn the start switch to the ON position.
5
pressure sensor
Between PFUEL (2) and (3),
Voltage or between ECM1 J1 (87) Sensor output 0.2 to 4.6 V
and (58)
40-368 HD465-8, HD605-8


Circuit diagram related to common rail pressure sensor
HD465-8, HD605-8 40-369


Action level Failure code Common Rail Pressure Sensor Low Error
Failure
Details of fail-
Low pressure error is sensed in the circuit of the common rail pressure sensor.
ure
Effect on the
machine
36401)
Related infor-
mation

connector

Defective common rail 2. Disconnect connector PFUEL.
2 3. Turn the start switch to the ON position.
pressure sensor
If failure code [CA452] changes to [CA451], the sensor is defective.

Open circuit in wiring har- 2. Disconnect connectors PFUEL and ECM1 J1, and connect T adapter to each female
3 side.
ness
Resistance Between ECM1 J1 (female) (82) and PFUEL (female) (1) Max. 1 Ω

2. Disconnect connectors PFUEL and ECM1 J1, and connect T adapter to either female
4
ness
Between ground and PFUEL (female) (2) or ECM1 J1
(female) (87)

2. Disconnect connectors ECM1 J1 and PFUEL, and connect T-adapter to female side
5
ness
Resistance No continuity
pin (87)
40-370 HD465-8, HD605-8

HD465-8, HD605-8 40-371


Action level Failure code Common Rail Pressure Sensor Supply Voltage High Error
Failure
Details of fail-
High voltage error occurs in power supply (5 V) of common rail pressure sensor.
ure
Effect on the
machine
Related infor- After the repair is completed, use this procedure to remove the failure code.
mation Procedure: Turn the starting switch to the ON position.

connector

Defective common rail
2 If this failure code is no longer shown, the sensor is defective.
pressure sensor
REMARK
Many other failure codes appear at the same time because the connector is discon-
nected. delete

2. Disconnect connector ECM1 J1.
Defective sensor or wiring
3 If this failure code is not shown, the wiring harness is defective.
harness
REMARK
nected. delete

2. Disconnect connector ECM1 J1, and connect T adapter to the male side.
4 Defective engine controller 3. Turn the starting switch to the ON position.
4.75 to 5.25
Voltage Between ECM1 J1 (male) (82) and (58)
V
40-372 HD465-8, HD605-8

HD465-8, HD605-8 40-373


Action level Failure code Common Rail Pressure Sensor Supply Voltage Low Error
Failure
Details of fail-
Low voltage error occurs in power supply (5 V) of common rail pressure sensor.
ure
Effect on the
machine
mation Procedure: Turn the starting switch to the ON position.

connector

Defective common rail
2 If this failure code is no longer shown, the sensor is defective.
pressure sensor
REMARK
nected. delete

3 If this failure code is not shown, the wiring harness is defective.
harness
REMARK
nected. delete

4.75 to 5.25
Resistance Between ECM1 J1 (male) (82) and (58)
V
40-374 HD465-8, HD605-8

HD465-8, HD605-8 40-375


Action level Failure code Common Rail Pressure High Error 1
Failure
Details of fail-
High pressure error (indicated pressure is higher than expected) of common rail pressure is sensed.
ure
Function of
None in particular
Controller
Effect on the
machine
q If failure code [CA451] or [CA452] is shown, the common rail pressure sensor may have an electrical
defect. Troubleshoot for it first.
mation q Common rail pressure detected by the common rail pressure sensor can be checked by the monitoring

1 Fuel used may not be in specification. Speak with operator.
specification
Defective mechanical sys-
2 tem of common rail pres- Common rail pressure sensor may be mechanically defective.
sure sensor
3 Defective overflow valve Inspect the overflow valve for spring damage, seat wear, or a stuck ball.
4 Obstructed overflow piping Inspect the overflow piping. It may be defective.
5 Defective pressure limiter Pressure limiter may be mechanically defective.
40-376 HD465-8, HD605-8


Action level Failure code Crankcase Pressure High Error 1
Failure
Details of fail-
High pressure error (level 1) in crankcase is sensed.
ure
Function of
None in particular
Controller
Effect on the
None in particular
machine
q If failure code [CA1843] or [CA1844] is shown, the crankcase pressure sensor system may be defective.
q Signal voltage from the crankcase pressure sensor can be checked by the monitoring function. (Code:
mation q Pressure detected by the crankcase pressure sensor can be checked by the monitoring function. (Code:
48400)

1 Obstructed KCCV filter Replace KCCV filter.
Obstructed KCCV gas pip- The failure is removed after KCCV filter replacement, and a white oil material is found in
2
ing KCCV, it may block KCCV blowby gas piping. Troubleshoot for coolant leaks.

Defective crankcase pres- 2. Insert T-adapter into connector PCCV.
3 3. Turn the starting switch to ON position.
sure sensor
Voltage Between PCCV (3) and (2) 0.3 to 4.7 V
The failure remains after KCCV filter replacement, and Crankcase Pressure High Error 1
or 2 is shown, troubleshoot "ENGINE OIL CONSUMPTION IS EXCESSIVE". See
4 Increased blowby gas
TROUBLESHOOT ENGINE (S-MODE). Possibilities are piston ring wear or damage, oil
leak from VGT, valve guide and seal wear or damage.
HD465-8, HD605-8 40-377

Circuit diagram related to crankcase pressure sensor
40-378 HD465-8, HD605-8


Action level Failure code Crankcase Pressure High Error 2
Failure
Details of fail-
High pressure error (level 2) in crankcase is sensed.
ure
Function of
Derates the engine power for operation.
Controller
machine q There may be oil leaks from seals or the level gauge.
48400)

2

sure sensor
HD465-8, HD605-8 40-379

40-380 HD465-8, HD605-8


Action level Failure code Common Rail Pressure Low Error 1
Failure
Details of fail-
No-pressure error (level 1) is sensed in the supply pump.
ure
Function of
None in particular
Controller
Effect on the q The engine does not start, or is hard to start.
q If other failure code is shown at the same time, troubleshoot for it first.
Related infor-
mation

1 Fuel used may be out of specification, examine it.
specification
q For details to troubleshoot, see Note 1, How to Test the Low-pressure Circuit Devices.
q To test the fuel low-pressure circuit pressure, see TEST AND ADJUST, "FUEL PRES-
Defective fuel low-pres- SURE TEST".
2
sure circuit device
Fuel low-pressure circuit pressure (high idle
or load equivalent to rated operation) 0.15 to 0.30 MPa {1.5 to 3.0 kg/cm2}
3 Clogged filter, or strainer For details to troubleshoot, see Note 2, How to Test the Low-pressure Circuit Devices.
connector

5
Resistance

2. Disconnect connectors ECM1 J1 and P1_PCV1, and connect T adapter to each
6
ness
Resistance

Hot short circuit in wiring 2. Insert T adapter into connector ECM1 J1.
harness

Short circuit in wiring har- 2. Disconnect connector ECM1 J1, and connect T adapter to the female side.
8
tor)
HD465-8, HD605-8 40-381


9
Resistance

10
ness
Resistance

harness

12
tor)
Defective common rail Inspect for damage of the wiring harness because the common rail pressure sensor may
13
pressure sensor be defective.
To test the pressure limiter leakage quantity, see TEST AND ADJUST, "FUEL RETURN
RATE AND LEAKAGE TEST".
14 Defective pressure limiter
Pressure limiter leakage quantity (speed in
Max. 10 cc/min
rated operation or equivalent (stall load))
To measure the limit return rate (spill) from injector, see TEST AND ADJUST, "FUEL
RETURN RATE AND LEAKAGE TEST".
1600 rpm 960 cc/min
15 Defective injector 1700 rpm 1020 cc/min

Limit return
Speed in rated operation or
rate (spill) 1800 rpm 1080 cc/min
equivalent (stall load)
from injector
1900 rpm 1140 cc/min
To test if either the supply pump A or supply pump B is defective, see TEST AND
16 Defective supply pump
ADJUST, "SUPPLY PUMP TEST".
How to Test the Low-pressure Circuit Devices

<Using the check sheet>
Perform the above troubleshooting, and also record the results of the check sheet, using the attached "Check Sheet for
No-pressure Error".
Note 1: For the low pressure circuit device, investigate the following items.
q Fuel level
q Clogged fuel tank breather
q Stuck or worn feed pump or clogged filter.
q Leakage or obstruction of low pressure fuel piping
q Malfunction of the bypass valve (See the figure below.)
q Obstructed fuel filter
q Fuel is mixed into the oil filter (fuel leakage in the head cover)
40-382 HD465-8, HD605-8

Position of the overflow valve (1), bypass valve (2), and fuel inlet joint (3)
Overflow valve (1): Spring is seen through each holes.

Bypass valve (2): Spring is seen through the hole on the nut side.
Fuel inlet joint (3): Gauze filter is seen through each hole.
Note 2: Perform the following to check, clean, and replace the filters and strainers.
1. Gauze filter: Disassemble and check and clean if clogged.
2. Strainer on upstream side of gauze filter: If gauze filter is clogged, clean upstream strainer as well.
3. Fuel filter: If the failure is not solved by performing the steps in 1 and 2 above, replace the fuel filter.
Check Sheet for No-pressure Error
Model Work No.

Model and serial No. Date inspected
Engine SAA6D170E-7 Service meter
Engine serial No. Name
No
Go
A. Inspect visually go
od
od
1 External fuel leaks
2 Clogged fuel tank breather
HD465-8, HD605-8 40-383

No
B. Inspect by the machine monitor (Failure record, monitor information, cylinder Cutout Mode Operation) Good
good
3 Inspect the failure code
Inspect the monitor information
Standard value Measured No
Code Item shown Testing conditions Unit Good
for new machine value good
Low idle r/min 750 (±50)
1002 Engine speed High idle r/min 2270 (±50)
Torque converter stall r/min 1931 (±100)
Accelerator pedal Low idle % 0

31701
position High idle % 100
4 Inject Fueling Com-
18600 mand (Unit of Torque converter stall mg/st - - -
weight)
Rail Pressure Com-
36200 Torque converter stall MPa -
mand
Common rail pres-
sure
36500 Boost pressure Torque converter stall kPa - - -
Engine coolant tem-
4107 Low idle °C - - -
perature
Check of Cylinder Cutout Mode Operation (engine speed)
Func- Standard value Measured No
Cutout cylinder Testing conditions Unit Good
tion for new machine value good
No. 1 cylinder Low idle r/min - - -
Set No. 2 cylinder Low idle r/min - - -
5
cutout
to No. 3 cylinder Low idle r/min - - -
each No. 4 cylinder Low idle r/min - - -
cylin-
der No. 5 cylinder Low idle r/min - - -

C. Check of fuel circuit pressure Testing conditions Unit Good
MPa 0.15 to 0.30
6 Fuel pressure High idle
{kg/cm2} {1.5 to 3.0}
No
D. Inspect strainer and filter Good
good
7 Visually inspect the strainer
8 Visual check of gauze filter
9 Visual check of fuel filter
10 Visual check of bypass valve
40-384 HD465-8, HD605-8

E. Check of leakage and return Standard value Measured No

Testing conditions Unit Good
rate for new machine value good
Leakage from the pressure Load equivalent to rated opera-
11 cc/min Max. 10
limiter tion (at stall)
Torque converter stall: 1600 rpm cc/min 960
Fan speed:
12 Return rate from injector Torque converter stall: 1800 rpm cc/min 1080
Return rate:
Circuit diagram related to fuel system
HD465-8, HD605-8 40-385


Action level Failure code Turbocharger Speed High Error 2
Failure
Details of fail-
Turbocharger turns at abnormally high speed.
ure
Function of
Operates the engine with turbocharger speed at a set value of 130000 (rpm).
Controller
Effect on the
None in particular
machine
k VGT becomes hot (Min. 500 °C). Be careful not to become burned.
q Speed detected by the turbocharger speed sensor can be checked by the monitoring function. (Code:
mation q Sensor output is a pulse waveform, which cannot be measured with a multimeter.

connector

Hot short circuit in wiring 2. Disconnect connector ECM1 J1, and connect T adapter to the female side.
harness
Voltage Between ECM1 J1 (female) (17) and ground Max. 1 V

2. Disconnect connectors ECM1 J1 and VGT REV, and connect T adapter to either
Short circuit in wiring har- female side.
3
ness
VGT REV (female) (1) and (2)

Defective VGT speed sen- 2. Disconnect connector VGT REV, and connect T adapter to the female side.
4
sor 600 to 1600
Resistance Between VGT REV (female) (1) and (2)
Ω
Defective installation of
Inspect the installation of the turbocharger speed sensor (loose), or speed sensor parts
5 sensor or defective speed
(VGT internal parts) because deformation from heat may occur.
sensor parts
Inspect if the VGT shaft can rotate (manually move the VGT's blade axially and verti-
6 Mechanical failure of VGT
cally).
Defective VGT or turbocharger speed sensor. (Replace VGT and turbocharger speed
7 Defective VGT
sensor at the same time.)
40-386 HD465-8, HD605-8

Circuit diagram related to turbo speed sensor
HD465-8, HD605-8 40-387


Action level Failure code Turbocharger Speed Low Error
Failure
Details of fail-
Turbocharger turns at abnormally low speed.
ure
Function of
Operates the engine with turbocharger speed at a set value of 130000 (rpm).
Controller
Effect on the
None in particular
machine
k VGT becomes hot (Min. 500 °C). Be careful not to become burned.
Related infor- q Speed detected by the turbocharger speed sensor can be checked by the monitoring function. (Code:
mation 48100)
Procedure: Start the engine, and run the engine speed at 1200 rpm and higher.

connector

2. Disconnect connectors ECM1 J1 and VGT REV, and connect T adapter to each
female side.
2 Between ECM1 J1 (female) (17) and VGT REV (female)
ness Max. 1 Ω
(1)
Resistance
Between ECM1 J1 (female) (16) and VGT REV (female)
Max. 1 Ω
(2)

female side.
3 Between ground and ECM1 J1 (female) (17) or VGT REV
ness Min. 1 MΩ
(female) (1)
Resistance
Between ground and ECM1 J1 (female) (16) or VGT REV
Min. 1 MΩ
(female) (2)

Hot short circuit in wiring 2. Disconnect connector ECM1 J1, and connect T adapter to the female side.
harness
Voltage Between ECM1 J1 (female) (17) and ground Max. 1 V

5
ness
VGT REV (female) (1) and (2)

Defective VGT speed sen- 2. Disconnect connector VGT REV, and connect T adapter to the female side.
6
sor 600 to 1600
Resistance Between VGT REV (female) (1) and (2)
Ω
40-388 HD465-8, HD605-8


Inspect the installation of the turbocharger speed sensor (loose), or speed sensor parts
7 sensor or defective speed
(VGT internal parts) because deformation from heat may occur.
sensor parts
Inspect if the VGT shaft can rotate (manually move the VGT's blade axially and verti-
8 Mechanical failure of VGT
cally).
Defective VGT or turbocharger speed sensor. (Replace VGT and turbocharger speed
9 Defective VGT
sensor at the same time.)
Circuit diagram related to turbo speed sensor
HD465-8, HD605-8 40-389


Action level Failure code Engine NE Speed Sensor Error
Failure
Details of fail-
Error occurs in the signal from engine NE speed sensor.
ure
Function of
Operates the engine by Bkup speed sensor signal.
Controller
Effect on the q Engine stops (when Bkup speed sensor is also defective).
machine q When the engine is stopped, the engine will not start again (when Bkup speed sensor is also defective.)
q Engine speed can be checked by the monitoring function. (Code: 01002)
Related infor-
q Speed sensor senses holes of the flywheel and calculates engine speed.
mation

connector

2. Disconnect connectors ECM1 J1 and NE, and connect T adapter to each female side.
2
ness

Ground fault in wiring har- 2. Disconnect connectors ECM1 J1 and NE, and connect T adapter to either female side.
3
ness Between ground and ECM1 J1 (female) (31) or NE
(female) (3)

Hot short circuit in wiring 2. Disconnect connector NE, and connect T adapter to the female side.
harness

2. Disconnect connectors ECM1 J1 and NE, and connect T adapter to either female side.
Short circuit in wiring har- Between ECM1 J1 (female) (79) and (31), or between NE
5 Min. 1 MΩ
ness (female) (1) and (3)
Resistance
Min. 1 MΩ
6 Perform checks since the flywheel installation may be defective (loose).
wheel
7 speed sensor or defective Inspect the engine NE speed sensor for possible damage or mount failure (loose).
installation
40-390 HD465-8, HD605-8


If there is no failure found by these checks, the engine NE speed sensor may be defec-
tive. (Since this is an internal failure, you cannot troubleshoot.)
REMARK
Defective engine NE In normal condition, output from the speed sensor is pulse voltage of 5 V, which can-
8 q
HD465-8, HD605-8 40-391


Action level Failure code Intake Air Temperature Sensor High Error
Failure
Details of fail-
High voltage error occurs in signal circuit of the intake air temperature sensor.
ure
Function of
Sets intake air temperature to a set value (25 °C) for operation.
Controller
Effect on the
None in particular
machine
q Temperature detected by intake air temperature sensor can be checked by the monitoring function.
(Code: 18400)
Related infor-
mation
q When the sensor connector is disconnected, this failure code and [CA357] are shown at the same time.

connector

2. Disconnect connector MAF, and connect T adapter to the male side.
-30 °C 25 to 28 kΩ
Between MAF (male) (3) 0 °C 5.5 to 6.1 kΩ

Defective mass air flow and (4) Intake temperature -
2 25 °C 1.9 to 2.1 kΩ
and temperature sensor Resistance value character-
Resistance istics 40 °C 1.1 to 1.2 kΩ
100 °C 180 to 185 Ω
Between MAF (male) (3)
and ground (sensor body)

2. Disconnect connectors ECM1 J1 and MAF, and connect T adapter to each female
3
ness
Between ECM1 J1 (female) (61) and MAF (female) (4) Min. 1 MΩ
Resistance
Between ECM1 J1 (female) (56) and MAF (female) (3) Min. 1 MΩ

Hot short circuit in wiring 3. Insert T adapter into connector ECM1 J1, or connect T adapter to the female side of
4 connector MAF.
harness
Between ECM1 J1 (61) and (56), or between MAF
Voltage Max. 5.25 V

5
ness
pin (61)
40-392 HD465-8, HD605-8


HD465-8, HD605-8 40-393


Action level Failure code Intake Air Temperature Sensor Low Error
Failure
Details of fail-
Low voltage error occurs in signal circuit of the intake air temperature sensor.
ure
Function of
Sets intake air temperature to a set value (25 °C) for operation.
Controller
Effect on the
None in particular
machine
q Temperature detected by intake air temperature sensor can be checked by the monitoring function.

connector

2. Disconnect connector MAF, and connect T adapter to the male side.
-30 °C 25 to 28 kΩ
Between MAF (male) (3) 0 °C 5.5 to 6.1 kΩ

Defective mass air flow and (4) Intake temperature -
2 25 °C 1.9 to 2.1 kΩ
and temperature sensor Resistance value character-
Resistance istics 40 °C 1.1 to 1.2 kΩ
100 °C 180 to 185 Ω
Between MAF (male) (3)
and ground (sensor body)

2. Disconnect connectors ECM1 J1 and MAF, and connect T adapter to either female
3
ness
Between ground and ECM1 J1 (female) (61) or MAF
(female) (4)

4
ness
pin (61)
40-394 HD465-8, HD605-8

HD465-8, HD605-8 40-395


Action level Failure code Engine Controller Internal Temperature Sensor High Error
Failure
Details of fail-
High voltage error is generated in signal circuit of the engine controller internal temperature sensor.
ure
Function of
None in particular
Controller
Effect on the
None in particular
machine
q Temperature detected by the engine controller internal temperature sensor can be checked by the mon-
Related infor- itoring function. (Code: 18900)

1 Incorrect use of controller Inspect if the controller is used in a high temperature environment.
40-396 HD465-8, HD605-8


Action level Failure code Engine Controller Internal Temperature Sensor Low Error
Failure
Details of fail-
Low voltage error is sensed in signal circuit of the internal temperature sensor of the engine controller.
ure
Function of
None in particular
Controller
Effect on the
None in particular
machine

1 Incorrect use of controller Inspect if the controller is used in a high temperature environment.
HD465-8, HD605-8 40-397


Action level Failure code Engine Backup Speed Sensor Phase Error
Failure
Details of fail- Engine controller senses a phase error by signal from the engine Bkup speed sensor. (Compared with a
ure signal from NE speed sensor, the phase does not match.)
Function of
Controls by a signal from the engine NE speed sensor.
Controller
Effect on the q Engine operation stops during operation (when NE speed sensor is also defective).
machine q When the engine is stopped, the engine will not start again (when NE speed sensor is also defective).
q Speed sensor senses holes of the flywheel and calculates engine speed.
Related infor-
q To replace the Bkup speed sensor, replace the fuel supply pump. (See DISASSEMBLY AND ASSEM-
mation
BLY, REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY.)

connector

2. Disconnect connectors ECM1 J1 and NE, and connect T adapter to each female side.
2
ness

Ground fault in wiring har- 2. Disconnect connectors ECM1 J1 and NE, and connect T adapter to either female side.
3
ness Between ground and ECM1 J1 (female) (31) or NE
(female) (3)

Hot short circuit in wiring 2. Disconnect connector NE, and connect T adapter to the female side.
harness

2. Disconnect connectors ECM1 J1 and NE, and connect T adapter to either female side.
Short circuit in wiring har- Between ECM1 J1 (female) (79) and (31), or between NE
5 Min. 1 MΩ
ness (female) (1) and (3)
Resistance
Min. 1 MΩ
6 Perform checks since the flywheel installation may be defective (loose).
wheel
7 speed sensor or defective Inspect the engine NE speed sensor for possible damage or mount failure (loose).
installation
40-398 HD465-8, HD605-8


If there is no failure found by these checks, the engine NE speed sensor may be defec-
REMARK
Defective engine NE In normal condition, output from the speed sensor is pulse voltage of 5 V, which can-
8 q

9 Defective resistance 2. Disconnect connector P1_G_RES, and connect T adapter to the male side.

2. Disconnect connectors ECM1 J1, P1_G, and P1_G_RES, and connect T adapter to
each female side.
ness

2. Disconnect connectors ECM1 J1 and P1_G, and connect T adapter to either female
11
ness
(female) (C)

2. Disconnect connectors P1_G and P1_G_RES, and connect T adapter to the female
Hot short circuit in wiring side of P1_G.
12
harness 3. Turn the starting switch to the ON position.

2. Disconnect connectors ECM1 J1, P1_G and P1_G_RES, and connect T adapter to
the female side of ECM1 J1 or P1_G.
ness Min. 1 MΩ
P1_G (female) (A) and (C)
Resistance
Min. 1 MΩ
P1_G (female) (B) and (C)
Bkup speed sensor or
14 Check the engine Bkup sensor for possible damage or mount failure (loose).
(mounted loosely)
Defective engine Bkup If there is no failure found by these checks, the engine Bkup speed sensor may be defec-
15
speed sensor tive. (Since this is an internal failure, you cannot troubleshoot.)
If there is no failure found by these checks, the supply pump is defective. (Since this is an
internal failure, you cannot troubleshoot.)
HD465-8, HD605-8 40-399

40-400 HD465-8, HD605-8


Action level Failure code Engine Backup Speed Sensor Error
Failure
Details of fail-
Error is sensed in engine Bkup speed sensor circuit.
ure
Function of
Operates the engine by signal from the engine NE speed sensor.
Controller
q Engine operation stops during operation (when NE speed sensor is also defective).
Effect on the
q When the engine is stopped, the engine will not start again (when NE speed sensor is also defective).
machine
q Engine is hard to start (when NE speed sensor is normal).
q The sensor has electric circuits, not coils, therefore you cannot troubleshoot the resistance of the speed
sensor with a multimeter.
Related infor-
mation

connector

2 Defective resistance 2. Disconnect connector P1_G_RES, and connect T adapter to the male side.

2. Disconnect connectors ECM1 J1, P1_G, and P1_G_RES, and connect T adapter to
each female side.
ness

2. Disconnect connectors ECM1 J1 and P1_G, and connect T adapter to either female
4
ness
(female) (C)

2. Disconnect connectors P1_G and P1_G_RES, and connect T adapter to the female
Hot short circuit in wiring side of P1_G.
5
harness 3. Turn the starting switch to the ON position.

2. Disconnect connectors ECM1 J1, P1_G and P1_G_RES, and connect T adapter to
Short circuit in wiring har- the female side of ECM1 J1 or P1_G.
6
ness
Between ECM1 J1 (female) (78) and (18), or between Min. 1 MΩ
Resistance
Between ECM1 J1 (female) (54) and (18), or between Min. 1 MΩ
HD465-8, HD605-8 40-401


7 Bkup speed sensor or Check the engine Bkup sensor for possible damage or mount failure (loose).
(mounted loosely)
If there is no failure found by these checks, the engine Bkup speed sensor may be defec-
REMARK
8 q
Circuit diagram related to engine Bkup speed sensor
40-402 HD465-8, HD605-8


Action level Failure code Engine Controller Partial Data Lost Error
Failure
Details of fail-
Internal failure is sensed in the engine controller.
ure
Function of
None in particular
Controller
q Engine operates correctly, however, the engine may stop during operation or is not able to start after it
Effect on the
is stopped.
machine
q Engine controller cannot keep the internal data correctly.
q Engine controller internal data (KDPF data etc.) may be lost. Proper remedy is required after resetting
the error.
NOTICE
Related infor- Procedures after you set the error
mation Perform "Active Regeneration for Service". For details, see TEST AND ADJUST, "SERVICE MODE"
and "PROCEDURE TO OPERATE REGENERATION FOR SERVICE TEST MENU" under "SET AND

connector
2 Defective battery

Voltage
The battery disconnect switch may operate incorrectly.
Defective battery discon-
4 nect switch by incorrect
REMARK
operation This failure code is displayed when the power supply is shut down by using the battery
disconnect switch before the engine controller is normally shut down.
HD465-8, HD605-8 40-403

40-404 HD465-8, HD605-8

HD465-8, HD605-8 40-405


Action level Failure code CEN Communication Error
Failure
Details of fail-
Defective communication is sensed in the engine controller.
ure
q Closes EGR valve.
Function of
Controller
q Stops the drive of supply pump_2.
q When the key is in the ON position: Engine cannot be started.
Effect on the
machine

connector

2. Remove fuse BT3-20 (No.10).
2 Defective fuse q If the fuse BT3-20 (No. 10) is broken, the circuit probably has short circuit in the engine
controller.
q If the fuse BT3-24 (No. 12) is broken, the wiring harness probably has ground fault.
If the fuse is not broken, the check that follows is not required.
Between ECM2 J2 (male) (1) and (49) Max. 1 Ω
Resistance
Between ECM2 J2 (male) (28) and (73) Max. 1 Ω
Make sure ground terminal ER10 is tight and free of rust.
Defective power supply to 3. Turn the starting switch to the ON position.
4
the transmission controller 4. Troubleshoot for failure code [CA441] when any error is found.
Between ECM2 J2 (female) (1) and (49) 20 to 30 V

Resistance
Between ECM2 J2 (female) (28) and (73) 20 to 30 V

2. Disconnect connectors ECM1 J1 and ECM2 J1, and connect T adapter to each female
side.
5 Between ECM1 J1 (female) (69) and ECM2 J1 (female)
ness Max. 1 Ω
(69)
Resistance
Between ECM1 J1 (female) (93) and ECM2 J1 (female)
Max. 1 Ω
(93)
40-406 HD465-8, HD605-8


2. Disconnect connectors ECM1 J1 and ECM2 J1, and connect T adapter to either
female side.
6 Between ground and ECM1 J1 (female) (69) or ECM2 J1
ness Min. 1 MΩ
(female) (69)
Resistance
Between ground and ECM1 J1 (female) (93) or ECM2 J1
Min. 1 MΩ
(female) (93)

2. Disconnect connector CEN11_RES and CEN12_RES, and connect T-adapter to male
side.
7 Defective resistance
Between CEN11_RES (male) (A) and (B) 120 ± 12 Ω
Resistance
Between CEN12_RES (male) (A) and (B) 120 ± 12 Ω
Circuit diagram related to multi controller
HD465-8, HD605-8 40-407

40-408 HD465-8, HD605-8


Action level Failure code Multi-controller ID Harness Key Error
Failure
Details of fail-
The controller and ID harness are not consistent
ure
Function of
Stops the effect.
Controller
Effect on the
When key is in the ON position: Engine cannot be started.
machine
mation Procedure: Turn the start switch to the ON position.

connector

Open circuit in wiring har- 2. Disconnect connector ECM1 J2, and connect T adapter to the female side of ECM1
2 J2.
ness
Resistance Between ECM1 J2 (female) (62) and (89) Max. 1 Ω
Circuit diagram related to engine starting circuit
HD465-8, HD605-8 40-409


Action level Failure code KDOC Abnormality
Failure
Details of fail- KDOC inlet and outlet temperature sensors show the almost same temperature (difference in temperature
ure is in approximately 10 °C).
q Closes EGR valve.
Controller q Stops regeneration control.
q Stops the fuel dosing.
Effect on the
machine
k KDPF and KDOC become hot (Min. 500 °C). Be careful not to become burned.
q If the failure code [CA3313], [CA3314], or [CA3315] is shown, KDOC inlet temperature sensor may be
defective. Troubleshoot for [CA3313], [CA3314], or [CA3315].
q If the failure code [CA3316], [CA3317], or [CA3318] is shown, KDOC outlet temperature sensor may be
mation NOTICE
q After you investigate the cause of the problem and complete the repair, perform Loaded Diag-
nostics Operation To Remove Failure Code. This ensures the failure code is removed. (This fail-
ure code is not removed when you only turn the start switch to the ON position.)
q This failure code is removed when you perform this procedure, see TEST AND ADJUST, "SER-
VICE MODE" and "OPERATE ENGINE CONTROLLER ACTIVE FAULT CLEAR TEST MENU" in the
1. Check if KDPF is correctly attached to the exhaust system.

1 Defective KDOC
2. Check if KDOC is correctly attached to KDPF.
Loaded Diagnostics Operation To Clear Failure Code

Use the procedures that follow to make sure the repair is completed.
(Make sure that this failure code is removed after this procedure.)
k Put the machine on a level ground, set the parking brake switch to the "PARK" position, and chock the tires.
1. Turn the start switch to the ON position, and start the engine.
2. Run the engine at low idle speed for approximately 1 minute.
3. Set the park brake switch to the "TRAVEL" position.
NOTICE
Engine speed does not go to approximately 2270 rpm at high idle speed until the park brake is released.
4. Monitor the KDOC inlet and outlet temperatures with the monitor function. Run the engine at high idle speed (approximately
2270 rpm) with the brake pedal depressed until temperatures go to 200 °C or higher.
REMARK
q Temperature detected by KDOC inlet temperature sensor can be checked by the monitoring function. (Code: 47300)
q Temperature detected by KDOC outlet temperature sensor can be checked by the monitoring function. (Code: 47400)
NOTICE
KDOC inlet temperature of 250 °C or higher is required to remove the failure code.
5. After both KDOC inlet temperature and KDOC outlet temperature reach 200 °C or higher, continuously run the engine at
high idle speed for another 15 minutes.
40-410 HD465-8, HD605-8

6. Check that this failure code is removed.
REMARK
q If this failure code is removed, the repair is completed.
q If this failure code is not removed, go back to troubleshooting.
Circuit diagram related to KDOC temperature sensor
HD465-8, HD605-8 40-411


Action level Failure code Defective Regeneration
Failure
KDOC is not efficient, (catalysis) decreases. (Soot in KCSF does not burn correctly, because the KDOC
Details of fail-
outlet temperature does not rise. During regeneration, the normal KDOC inlet temperature is 250 to 400 °C
ure
and the KDOC outlet temperature is 450 to 600 °C)
q Closes EGR valve.
Function of
Controller
Effect on the
machine
k KDPF and KDOC become hot (Min. 500 °C). Be careful not to become burned.
q All of KDOC inlet temperature, KDOC outlet temperature and KDPF outlet temperature during idle (no
regeneration) are 100 to 250 °C. Each temperature difference is approximately 10 °C. (KDOC inlet tem-
perature > KDOC outlet temperature > KDPF outlet temperature).
q During manual stationary regeneration (normal), KDOC inlet temperature is 250 to 400 °C, and both
KDOC outlet temperature and KDPF outlet temperature are 450 to 600 °C.
q During manual stationary regeneration without dosing fuel injection (dry KDOC), all of KDOC inlet and
Related infor- outlet temperatures, and KDPF outlet temperature are 250 to 400 °C.
mation q Failure code [CA2637] may show at the same time, but troubleshoot for this failure code.
q When the soot accumulation level is 3 or less, Manual stationary regeneration is performed only from
Active Regeneration for Service.
q Make sure the repair is completed: When the KDOC is not replaced, start the engine and perform the
manual stationary regeneration.
NOTICE
q When KDOC is replaced, it not required to make sure the repair is completed.
q If KDOC of KDPF is replaced, set the "after KDOC change", then the repair is completed.

When KDPF cools down sufficiently or there are differences between KDOC outlet and
inlet temperature, or KDPF outlet temperature at idle, change the sensor. (no regenera-
tion)
REMARK
q Temperature detected by KDOC inlet temperature sensor can be checked by the
monitoring function. (Code: 47300)
Defective KDOC outlet q Temperature detected by KDOC outlet temperature sensor can be checked by the
1
temperature sensor monitoring function. (Code: 47400)
q Temperature detected by KDPF outlet temperature sensor can be checked by moni-
q To access KDOC inlet temperature sensor, KDOC outlet temperature sensor, and
KDPF outlet temperature sensor, see DISASSEMBLY AND ASSEMBLY, "REMOVE
AND INSTALL KDPF ASSEMBLY" and "DISASSEMBLE AND ASSEMBLE OF KDPF
ASSEMBLY".
40-412 HD465-8, HD605-8


Start the engine, accelerate from low idle speed to high idle speed twice, and then keep
the engine at high idle speed for 5 seconds.
REMARK
To check the exhaust gas color, See TEST AND ADJUST, "TEST EXHAUST GAS
Defective exhaust gas COLOR".
2
color If excess black smoke is seen at high idle or when the engine accelerates, perform
"KDPF GETS CLOGGED IN A SHORT TIME".
REMARK
If black smoke comes out when you accelerate the engine, but disappears at high idle
speed, there is no failure.
1. Remove KDPF.
2. Remove KDPF.
3. Blow air from KDOC outlet, and remove the discoloration on the ceramic surface in
the KDOC.
4. Inspect the ceramic in the KDOC for cracks.
5. If KDOC has cracks, KDOC is defective (replace KDOC).
Defective KDOC (discol- 6. Perform KDPF Memory Reset after installation or replacement of KDOC or KDPF. For
3
ored, crack, damage) details, see TEST AND ADJUST, "SET AND OPERATE OF MACHINE MONITOR",
"SERVICE MODE" and "PROCEDURE TO OPERATE THE TEST MENU (KDPF
MEMORY RESET)".
REMARK
The failure codes [CA1691] and [CA2637] do not appear after you set the KDPF Mem-
ory. At this point, the procedure to prevent dosing fuel injection is stopped, which was
activated when this failure code was shown.
When the KDOC is not replaced
2. Record the initial conditions of KDOC inlet and KDPF outlet temperature sensors.
Record temperatures during the manual stationary regeneration, and check the
KDOC outlet sensor for normal temperature. (See RELATED INFORMATION ON
TROUBLESHOOTING.)
5. From Service Menu of the machine monitor, display Diagnostic Tests screen, open
Active Regeneration for Service, and perform manual stationary regeneration.
(Manual stationary regeneration finishes in approx. 40 minutes.)
Defective KDOC (lowered 6. Turn the start switch to the OFF position.
4 7. Start the engine, and perform manual stationary regeneration. When the failure code
KDOC catalyzer function)
does not appear, set KDPF Memory and complete the troubleshooting.
8. If the failure code [CA2637] is shown after the manual stationary regeneration is
completed, the KDOC is defective. (Catalyzer function of KDOC is lowered. Replace
the KDOC.)
9. Set the KDPF Memory after replacement of the KDOC. For details, see TEST AND
ADJUST, "SET AND OPERATE OF MACHINE MONITOR", "SERVICE MODE" and
"PROCEDURE TO OPERATE THE TEST MENU (KDPF MEMORY RESET)".
REMARK
The failure codes [CA1691] and [CA2637] do not appear after you set the KDPF Mem-
ory. At this point, the procedure to prevent dosing fuel injection is stopped, which was
activated when this failure code was shown.
HD465-8, HD605-8 40-413


Failure
Details of fail- High voltage error occurs in power supply (5 V) of KDPF differential pressure sensor and KDPF outlet
ure pressure sensor.
q Operates the KDPF outlet pressure sensor at an estimate value (The controller may operate at 0 kPa
{0 kg/cm2}).
q Operates KDPF differential pressure sensor at an estimate value (The controller may operate at 0 kPa
Function of
Controller {0 kg/cm2}).
q Closes EGR valve.
Effect on the
machine

connector

position each time.
2
harness
REMARK
Ignore other failure codes caused when you disconnected the connector.
KDPF differential pressure (outlet pressure) sensor DPFP1
Connector
Accelerator pedal AS2

2. Disconnect connectors ECM1 J2, DPFP1, and AS2, and connect T adapter to either
3
ness
Between ground and ECM1 J2 (female) (8) or DPFP1
(female) (4)

2. Disconnect connectors ECM1 J2, DPFP1, and AS2, and connect T adapter to the
Short circuit in wiring har- female side of ECM1 J2.
4
ness
pin (8)
40-414 HD465-8, HD605-8


2. Disconnect connector DPFP1.
3. Insert T-adapter into connector ECM J2, or connect T-adapter to female side of
5 Defective engine controller connector DPFP1.
4. Turn the starting switch to ON position.
Between ECM1 J2 (8) and (32), or between DPFP1
Voltage 4.75 to 5.25V
Circuit diagram related to KDPF differential pressure and KDPF outlet pressure sensor
HD465-8, HD605-8 40-415


Failure
Details of fail- Low voltage error occurs in power supply (5 V) of KDPF differential pressure sensor and KDPF outlet dif-
ure ferential pressure sensor.
q Operates the KDPF outlet pressure sensor at an estimate value (The controller may operate at 0 kPa
{0 kg/cm2}).
q Operates the KDPF differential pressure sensor at an estimate value (The controller may operate at 0
Function of
Controller kPa {0 kg/cm2}).
q Closes EGR valve.
Effect on the
machine
q After this failure code is removed, turn the start switch to OFF to cancel the engine power derate.
Related infor- (Removal of the failure code does not cancel the derate.)

connector

position each time.
2
harness
REMARK
KDPF differential pressure (outlet pressure) sensor DPFP1
Connector
Accelerator pedal AS2

2. Disconnect connectors ECM1 J2, DPFP1, and AS2, and connect T adapter to either
3
ness
(female) (4)

2. Disconnect connectors ECM1 J2, DPFP1, and AS2, and connect T adapter to the
4
ness
pin (8)
40-416 HD465-8, HD605-8


3. Insert T-adapter into connector ECM J2, or connect T-adapter to female side of
5 Defective engine controller connector DPFP1.
Between ECM1 J2 (8) and (32), or between DPFP1
Voltage 4.75 to 5.25V
HD465-8, HD605-8 40-417


Action level Failure code Crankcase Pressure Sensor High Error
Failure
Details of fail-
High pressure error in the signal circuit of the crankcase pressure sensor.
ure
Function of
Sets the crankcase pressure sensor to the specified value (approximately 0 kPa ) for operation.
Controller
Effect on the
None in particular
machine
q If the failure code [CA352] or [CA386] is shown, the sensor power supply system may be defective.
48400)

connector

2. Disconnect connector PCCV.
Defective crankcase pres- 3. Turn the start switch to the ON position.
2
sure sensor
If the failure code changes from [CA1843] to [CA1844], crankcase pressure sensor is
defective.

Open circuit in wiring har- 2. Disconnect connectors ECM1 J1 and PCCV, and connect T adapter to each female
3 side.
ness
Resistance Between ECM1 J1 (female) (54) and PCCV (female) (2) Max. 1 Ω

Hot short circuit in wiring 2. Disconnect connector PCCV, and connect T adapter to the female side.
harness
Voltage Between PCCV (female) (3) and (2) Max. 1 V

2. Disconnect connectors ECM1 J1 and PCCV, and connect T adapter to either female
5
ness
PCCV (female) (1) and (3)
40-418 HD465-8, HD605-8

HD465-8, HD605-8 40-419


Action level Failure code Crankcase Pressure Sensor Low Error
Failure
Details of fail-
Low pressure error in the signal circuit of the crankcase pressure sensor.
ure
Function of
Sets the crankcase pressure sensor to the specified value (approximately 0 kPa ) for operation.
Controller
Effect on the
None in particular
machine
q If the failure code [CA352] or [CA386] is also shown, the sensor power supply system may be defective.
48400)

connector

2. Disconnect connectors ECM1 J1 and PCCV, and connect T adapter to each female
side.
2 Between ECM1 J1 (female) (78) and PCCV (female) (1) Max. 1 Ω
ness
Resistance Between ECM1 J1 (female) (54) and PCCV (female) (2) Max. 1 Ω
Between ECM1 J1 (female) (63) and PCCV (female) (3) Max. 1 Ω

3
ness
Between ground and ECM1 J1 (female) (63) or PCCV
(female) (3)

4
ness
PCCV (female) (2) and (3)

sure sensor
40-420 HD465-8, HD605-8

HD465-8, HD605-8 40-421


Action level Failure code KDPF Differential Pressure Sensor High Error
Failure
Details of fail-
High voltage is generated in the signal circuit of KDPF differential pressure sensor.
ure
q Operates the KDPF differential pressure sensor at an estimate value. (The controller may operate at 0 kPa
if other failure codes are shown at the same time.)
Function of
q Closes EGR valve.
Controller
Effect on the
machine
k KDPF becomes hot (Min. 500 °C). Be careful not to become burned.
q When the failure code [CA1695] is not displayed while at the same time the failure code [CA3133] is
displayed, open circuit may have occurred in GND line (defective contact of the connector).
Related infor- q Signal voltage from the KDPF differential pressure sensor can be checked by the monitoring function.
q Differential pressure detected by the KDPF differential pressure sensor can be checked by the monitor-
ing function. (Code: 47100)

connector

Defective KDPF differential 3. Turn the start switch to the ON position.
2
pressure sensor
If the failure code [CA1879] changes to [CA1881], the KDPF differential pressure sensor
is defective.

Open circuit in wiring har- 2. Disconnect connectors ECM1 J2 and DPFP1, and connect T adapter to each female
3 side.
ness
Resistance Between ECM1 J2 (female) (32) and DPFP1 (female) (1) Max. 1 Ω

Hot short circuit in wiring 2. Disconnect connector PDPF, and connect T adapter to the female side.
harness
Voltage Between DPFP1 (female) (2) and (1) Max. 1 V

2. Disconnect connectors ECM1 J2 and DPFP1, and connect T adapter to the female
Short circuit in wiring har- side of ECM1 J2.
5
ness
pin (41)
40-422 HD465-8, HD605-8


Circuit diagram related to KDPF differential pressure sensor
HD465-8, HD605-8 40-423


Action level Failure code KDPF Differential Pressure Sensor Low Error
Failure
Details of fail-
Low voltage is generated in the signal circuit of KDPF differential pressure sensor.
ure
Function of
q Closes EGR valve.
Controller
Effect on the
machine
q When the failure code [CA1696] is not displayed while at the same time the failure code [CA3134] is
displayed, the sensor connector may be disconnected or open circuit may have occurred in 5 V line (de-
fective contact of the connector).

connector

2. Disconnect connectors ECM1 J2 and DPFP1, and connect T adapter to each female
side.
2 Between ECM1 J2 (female) (32) and DPFP1 (female) (1) Max. 1 Ω
ness
Resistance Between ECM1 J2 (female) (8) and DPFP1 (female) (4) Max. 1 Ω
Between ECM1 J2 (female) (41) and DPFP1 (female) (2) Max. 1 Ω

2. Disconnect connectors ECM1 J2 and DPFP1, and connect T adapter to either female
3
ness
(female) (2)

2. Disconnect connectors ECM1 J2 and DPFP1, and connect T adapter to the female
4
ness
pin (41)
40-424 HD465-8, HD605-8


Defective KDPF differential 2. Insert T-adapter into connector DPFP1.
pressure sensor
Voltage Between DPFP1 (2) and (1) 0.5 to 4.5 V
HD465-8, HD605-8 40-425


Action level Failure code KDPF Differential Pressure Sensor In Range Error
Failure
Details of fail- Signal voltage from the KDPF differential pressure sensor does not show a correct value. (The signal volt-
ure age is in normal or in operation range.)
Effect on the
machine
q To start the engine again, wait until the system operation lamp goes off after you turn the start switch to
the OFF position. Then turn the start switch to the ON position.
Related infor- NOTICE
mation q After you investigate the cause of the problem and complete the repair, perform Loaded Diag-

connector
1. Remove KDPF the differential pressure sensor pipe.

2. Clean and unobstruct the KDPF differential pressure sensor pipe.
3. Inspect the KDPF differential pressure sensor pipe for cracks and damage.
4. Install the KDPF differential pressure sensor pipe with the ends connected correctly.
Defective KDPF differential 5. Perform Loaded Diagnostics Operation To remove the failure code.
2
pressure sensor pipe
REMARK
For details, see DISASSEMBLY AND ASSEMBLY, "REMOVE AND INSTALL KDPF
3 KDPF differential pressure
ASSEMBLY" and "DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY" to repair.
sensor
40-426 HD465-8, HD605-8


If the failure code [CA1881] is not shown, the wiring harness or engine controller is
defective.
REMARK
Ignore the failure codes other than this failure code.

2. Disconnect connector DPFP1, and connect the short socket adapter to the female
Defective wiring harness side.
4
or engine controller 3. Connect 5 V to the signal line. (Short-circuit pins (4) and (2) of connector DPFP1.)
REMARK
Prepare the short circuit electrical connector, referring to "RELATED INFORMATION ON
TROUBLESHOOTING", "PREPARATION OF SHORT CIRCUIT ELECTRICAL CON-
NECTOR (FOR FAILURE CODES [CA1883], [CB1883], [CA3135], AND [CB3135])".
If the failure code [CA1879] is not shown, the wiring harness or engine controller is
defective.
REMARK
Defective KDPF differential If the failure codes [CA1881] and [CA1879] are shown by the previous checks, KDPF dif-
5
pressure sensor ferential pressure sensor is defective.

REMARK
Perform this to make the engine controller recognize the difference in sensitivity of the sensor when the start switch is
turned to the ON position.
2. Turn the start switch to OFF position to stop the engine controller.
5. Stall torque converter continuously for approximately 1 minute as described below with accelerator pedal open position
100%.
1) Make sure the park brake switch is set to the "PARK" position. Be sure to set the gear shift lever to the "D" position
while you depress the brake pedal.
k Be sure to set the gear shift lever to D position, because the machine may start even with the brake pedal
depressed if the gear shift lever is set to a position other than D.
k Be sure to set the gear shift lever to D position while the torque converter is stalled to avoid internal damage
to the transmission controller.
HD465-8, HD605-8 40-427

2) Gradually depress the accelerator pedal with the brake pedal depressed to stall the torque converter.
NOTICE
Be sure that the torque converter oil does not overheat.
REMARK
Temperature detected by torque converter oil temperature sensor can be checked by the monitoring function. (Code:
30100)
REMARK
q If this failure code is not removed, perform previous steps 4 and 5, three times.
40-428 HD465-8, HD605-8


Action level Failure code KDPF Soot Accumulation High Error 1
Failure
KDPF soot accumulation level is 6 or 7, and a very large quantity of soot accumulates. Operator is required
Details of fail-
to immediately perform the manual stationary regeneration. (Replace the KDPF when the soot accumula-
ure
tion achieves level 8.)
q Closes EGR valve.
Function of
Controller
q Disables automatic regeneration.
Effect on the
machine
k KDOC and KDPF become hot (Min. 500 °C). Be careful not to become burned.
q During manual stationary regeneration, KDOC inlet temperature is approximately 250 to 400 °C, and
the two KDOC and KDPF outlet temperatures are approximately 450 to 600 °C.
q If other failure code is also shown (manual stationary regeneration included), troubleshoot for it first.
q When failure code [CA1922] is originally shown, the cord changes to [CA1921] during troubleshooting
of [CA1922]. In that case, see failure code [CA1922].
moval of the failure code does not cancel the derate.)
Time required for manual stationary regeneration depends on the soot accumulation quantity in the KCSF
as described below.
q Soot accumulation level 4: Approximately 40 minutes to 1 hour
q Soot accumulation level 5: Approximately 1 hour to 2 hours
q Soot accumulation level 6 or 7: Approximately 2 hours to 3 hours
Related infor- q Soot accumulation level 8: Manual stationary regeneration cannot be performed.
mation The cause of too much soot accumulation
1. Engine runs in a low load range where the temperature is not high enough to burn the soot in the KDPF.
q To prevent soot accumulation in the KDPF, a high engine load operation is required.
2. There is an engine failure that generates too much black smoke.
3. Regeneration Disable is set on the monitor screen.
q Regeneration is set to not be performed automatically, although soot accumulates. Cancel Regen-
eration Disable in a safe area to perform the regeneration, as it is required.
How to cancel the Regeneration Disable
Select Cancel of Regeneration Disable from Aftertreatment Devices Regeneration of the user menu, and
perform it. (For details, see Operation and Maintenance Manual, "Handle", "Procedures for Aftertreatment
Devices Regeneration Disable" in the "Handle the KDPF".)
1. Make sure the Regeneration Disable button is not pushed on the machine monitor. (If
pushed, cancel the Regeneration Disable.)
Defective soot accumula- 4. Perform manual stationary regeneration in the user mode. If manual stationary regen-
1 eration is not finished in 3 hours after the repair is complete, perform troubleshooting
tion level of KDPF (KCSF)
for failure code [CA2639].
5. Make sure that the failure code is removed after the manual stationary regeneration is
completed.
6. If the failure code [CA1921] or [CA2639] is displayed after manual stationary regener-
ation is completed, test the exhaust gas color.
HD465-8, HD605-8 40-429


q Test the exhaust gas color if the failure code [CA1921] or [CA2639] is shown after the
manual stationary regeneration is completed.
q To examine the exhaust gas color, See TEST AND ADJUST, "TEST EXHAUST GAS
COLOR".
q Perform the Regeneration Disable on the machine monitor when you test the exhaust
gas color.
Defective exhaust gas
2 1. Quickly accelerate the engine from low idle speed to high idle speed twice, and then
color
keep the engine at high idle speed for 5 seconds. If excessively black smoke comes
out at high idle when you accelerate, troubleshoot for "KDPF GETS CLOGGED IN A
SHORT TIME" in S mode. If black smoke comes out at when you accelerate but disap-
pears at high idle speed, there is no failure.
2. To complete the exhaust gas color check, cancel the Regeneration Disable.
3. Make sure that the failure code is not shown.
40-430 HD465-8, HD605-8


Action level Failure code KDPF Soot Accumulation High Error 2
Failure
q An abnormally large quantity of soot accumulates in KDPF. Stop the engine immediately for inspection
Details of fail-
and maintenance.
ure
q Soot accumulation achieves level 8. (KDPF is completely clogged with soot.)
q Closes EGR valve.
Function of
Controller
q Disables automatic regeneration, disables manual stationary regeneration
Effect on the
machine
moval of the failure code does not cancel the derate.)
Related infor- Time required for manual stationary regeneration depends on soot accumulation quantity in KCSF as
mation described below.
q Soot accumulation level 8: Manual stationary regeneration cannot be performed.
REMARK
If the soot accumulation level is 8, you need to check, clean or replace because KDPF is completely
clogged with soot.
Increased soot accumula- Increased soot accumulation because of regeneration cancel

1 tion because of regenera- REMARK
tion cancel Cancel the regeneration disable when it is pushed.
HD465-8, HD605-8 40-431


2. Make sure failure codes [CA2639], [CA1921], and [CA1922] are on the Abnormality
Record screen of the machine monitor.
Time period from when the failure code [CA2639] is displayed till when [CA1921] is dis-
played ≥ 360 sec. (KOMTRAX record) or ≥ 0.1 h (monitor record screen), and time period
from when [CA1921] is displayed till when [CA1922] is displayed ≥ 360 sec. (KOMTRAX
record) or ≥ 0.1 h (monitor record screen)
When the previous condition is achieved:
REMARK
Because accumulated soot quantity is high, you cannot perform KDPF regeneration.
1. Replace KCSF or KDPF.
2. Turn the start switch to the ON position, and perform reset of "KDPF Cleaning". (See
"PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)".)
Defective KDPF (KCSF) Make sure that failure code [CA1921] shows the change from [CA1922].
2
(KCSF replacement) If failure code [CA1922] persists, make sure the procedure for KDPF Memory Reset,
and then set the KDPF Clean again.
3. Perform reset of "KDPF Change". (See "PRECAUTIONS TO CLEAN AND REPLACE
KDPF (KCSF and KDOC)".)
4. Inspect for a defective KDPF differential pressure sensor.
7. If manual stationary regeneration from Active Regeneration for Service is completed
to remove moisture from KCSF, the repair is completed.
If the regeneration is not completed in 3 hours, perform troubleshooting for failure
code [CA2639]. Check that the failure code is cleared after the manual stationary
regeneration. If the failure code [CA1922], [CA1921], or [CA2639] is displayed, test
the exhaust gas color.
When the previous condition is not achieved, the accumulation of soot is less than the
indicated value.
If the accumulation of soot is less than the indicated value on the machine monitor:
2. Turn the start switch to the ON position, and perform reset of "KDPF Cleaning". (See
"PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)".)
Make sure that failure code [CA1921] shows the change from [CA1922].
If failure code [CA1922] persists, See the procedure for "KDPF Memory Reset", and
then perform "Clean KDPF" again. (See "PRECAUTIONS FOR CLEANING AND
REPLACING KDPF (KCSF and KDOC)".)
NOTICE
If KCSF or KDPF is not replaced do not set the KDPF Change.
Defective KDPF (KCSF)
3 (abnormal soot accumula-
tion)
5. Perform the manual stationary regeneration from the user mode.
When the manual stationary regeneration is completed correctly, the repair is
completed.
If the failure code [CA1922] is displayed again within 1 hour after the manual
stationary regeneration started, perform "Increased soot accumulation due to
canceling the regeneration" and "Defective KDPF (KCSF) (KCSF replacement)".
If the regeneration is not completed in 3 hours, perform troubleshooting for failure
code [CA2639]. Check that the failure code is cleared after the manual stationary
regeneration.
If the failure code [CA1922], [CA1921], or [CA2639] is displayed after manual
stationary regeneration is completed, test the exhaust gas color.
40-432 HD465-8, HD605-8


Defective KDPF differential
4 3. Inspect the KDPF differential pressure sensor pipe for cracks and damage.
5. Perform Loaded Diagnostics Operation To Make sure the failure is corrected.
q Test the exhaust gas color if the failure code [CA1921] or [CA2639] is shown after the
manual stationary regeneration is completed.
q To examine the exhaust gas color, See TEST AND ADJUST, "TEST EXHAUST GAS
COLOR".
q Perform the Regeneration Disable on the machine monitor when you test the exhaust
gas color.
Defective exhaust gas
5 1. Quickly accelerate the engine from low idle speed to high idle speed twice, and then
color
keep the engine at high idle speed for 5 seconds. If excessively black smoke comes
out at high idle when you accelerate, troubleshoot for "KDPF GETS CLOGGED IN A
SHORT TIME" in S mode. If black smoke comes out at when you accelerate but disap-
pears at high idle speed, there is no failure.
2. To complete the exhaust gas color check, cancel the Regeneration Disable.
3. Make sure that the failure code is not shown.
HD465-8, HD605-8 40-433


Action level Failure code Fuel Doser Solenoid 1 High Error
Failure
Details of fail-
High voltage error is sensed in circuit of the fuel doser solenoid valve 1 (shut off valve).
ure
Function of
Stops regeneration control.
Controller
Effect on the q Automatic regeneration is not performed.
machine q Manual stationary regeneration is disabled.
k Exhaust connector and KDPF become hot (Min. 500 °C). Be careful not to become burned.
q When the failure code [CA2732] is also displayed, open circuit may have occurred in GND line.
Related infor- q The circuit is configured so that this failure code is displayed, not the one indicating a "Low Error" when
mation the sensor connector is disconnected.

connector

2. Disconnect connector AFT_SOV1, and connect T adapter to the male side.
Defective fuel doser sole-
2
noid valve1 Between AFT1_SOV1 (male) (1) and (2) 4 to 6 Ω
Resistance
Between AFT1_SOV1 (1) and ground Min. 1 MΩ

2. Disconnect connectors ECM1 J1 and AFT1_SOV1, and connect T adapter to each
female side.
REMARK
Open circuit in wiring har- When the failure code [CA2732] is also shown, open circuit may occur in GND line.
3
ness
Between ECM1 J1 (female) (8) and AFT1_SOV1 (female)
Max. 1 Ω
(1)
Resistance
Between ECM1 J1 (female) (30) and AFT1_SOV1
Max. 1 Ω
(female) (2)

Hot short circuit in wiring 2. Disconnect connector AFT1_SOV1, and connect T adapter to the female side.
4 3. Turn the starting switch to the ON position.
harness
Voltage Between AFT1_SOV1 (female) (1) and (2) Max. 4.7 V
40-434 HD465-8, HD605-8

Circuit diagram related to fuel doser solenoid valve
HD465-8, HD605-8 40-435


Action level Failure code Fuel Doser Solenoid 1 Low Error
Failure
Details of fail-
Low voltage error is sensed in the circuit of the fuel doser solenoid valve 1 (shut off valve).
ure
Function of
Controller
Related infor- q This failure code is removed after the failure is eliminated. Then the fuel doser solenoid valve 1 operates
mation again when you turn the start switch to ON and then to the OFF position.

connector

2. Disconnect connector AFT_SOV1, and connect T adapter to the male side.
2
Resistance
Between AFT1_SOV1 (male) (1) and ground Min. 1 MΩ

2. Disconnect connectors ECM1 J1 and AFT1_SOV1, and connect T adapter to each
female side.
3 Between ECM1 J1 (female) (8) and AFT1_SOV1 (female)
ness Max. 1 Ω
(1)
Resistance
Between ECM1 J1 (female) (30) and AFT1_SOV1
Max. 1 Ω
(female) (2)

2. Disconnect connectors ECM1 J1 and AFT1_SOV1, and connect T adapter to either
4
ness
Between ground and ECM1 J1 (female) (8) or
AFT1_SOV1 (female) (1)

2. Disconnect connectors ECM1 J1 and AFT1_SOV1, and connect T adapter to the
5
ness
pin (8)
40-436 HD465-8, HD605-8

Diagram related to fuel doser

1A. Fuel doser-A
1B. Fuel doser-B
2A. Fuel supply line-A
2B. Fuel supply line-B
3A. Fuel doser solenoid valve 1-A (shut-off valve)
3B. Fuel doser solenoid valve 1-B (shut-off valve)
4A. Fuel doser solenoid valve 2-A (drain valve)
4B. Fuel doser solenoid valve 2-B (drain valve)
5A. Fuel doser pressure sensor-A
5B. Fuel doser pressure sensor-B
a: From fuel pump-A
b: From fuel pump-B
c: Fuel return
d: To fuel supply pump
e: From fuel supply pump
JB: Fuel pipe joint bolt
AFT1_PFUEL: Fuel doser pressure sensor-A connector
AFT1_SOV1: Fuel doser solenoid valve 1-A (shut-off valve) connec-
tor
AFT1_SOV2: Fuel doser solenoid valve 2-A (drain valve) connector
AFT2_PFUEL: Fuel doser pressure sensor-B connector
AFT2_SOV1: Fuel doser solenoid valve 1-B (shut-off valve) connector
AFT2_SOV2: Fuel doser solenoid valve 2-B (drain valve) connector
HD465-8, HD605-8 40-437


Action level Failure code Fuel Doser Solenoid 1 In Range Error
Failure
Details of fail- Fuel doser solenoid valve 1 does not operate correctly. (Dosing fuel pressure is not sufficiently lowered
ure because the valve on the fuel inlet side is not fully closed.)
Function of
Controller
q If the failure code [CA1927] or [CA1928] is shown, the fuel doser pressure sensor may be defective.
Related infor- Troubleshoot for it first.
Procedure: Turn the start switch from the OFF to the ON position to start the engine. Run the engine at
low idle for approximately 3 minutes.

connector

2. Disconnect fuel supply line (2A) from fuel doser (1A).
3. Disconnect connector AFT1_SOV1.
4. Replace fuel doser solenoid valve 1-A (shut-off valve) (3A).
Defective doser fuel shut 5. Connect disconnected connector AFT1_SOV1 to the replaced fuel doser solenoid
2 valve 1-A (shut-off valve) (3A).
off valve
If fuel leaks from the fuel connector to the fuel supply line (2A), the fuel doser solenoid
valve 1-A (3A) is defective. (shut-off valve)
40-438 HD465-8, HD605-8


1A. Fuel doser-A
1B. Fuel doser-B
a: From fuel pump-A
b: From fuel pump-B
c: Fuel return
JB: Fuel tube joint bolt
tor
HD465-8, HD605-8 40-439


Action level Failure code Dosing Fuel Pressure Sensor High Error
Failure
Details of fail-
Sensor voltage from the fuel doser pressure sensor is higher than specified value.
ure
Function of
Controller
q Signal voltage from the dosing fuel pressure sensor can be checked by the monitoring function. (Code:
mation q Pressure detected by the dosing fuel pressure sensor can be checked by the monitoring function.
(Code: 47600)
Procedure: Turn the start switch to the ON position. (Check the condition for 1 minute.) (Due to L01,
check by Abnormality Record screen.)

connector

2. Disconnect connector AFT1_PFUEL.
Defective Fuel doser pres- 3. Turn the start switch to the ON position.
2
sure sensor
If the failure code [CA1927] changes to [CA1928], the fuel doser pressure sensor is
defective.

2. Disconnect connectors ECM1 J1 and AFT1_PFUEL, and connect T adapter to each
Open circuit in wiring har- female side.
3
ness
Between ECM1 J1 (female) (57) and AFT1_PFUEL
(female) (2)

Hot short circuit in wiring 2. Disconnect connector AFT1_PFUEL, and connect T adapter to the female side.
harness
Voltage Between AFT1_PFUEL (female) (3) and (2) Max. 1 V

2. Disconnect connectors ECM1 J1 and AFT1_PFUEL, and connect T adapter to the
5
ness
pin (57)
40-440 HD465-8, HD605-8

Circuit diagram related to fuel doser pressure sensor
HD465-8, HD605-8 40-441


Action level Failure code Dosing Fuel Pressure Sensor Low Error
Failure
Details of fail-
Sensor voltage from the fuel doser pressure sensor is lower than necessary value.
ure
Function of
Controller
(Code: 47600)
Procedure: Turn the start switch to the ON position. (Check the condition for 1 minute.) (Due to L01,
check by Abnormality Record screen.)

connector

2. Disconnect connectors ECM1 J1 and AFT1_PFUEL, and connect T adapter to each
female side.
2 (female) (1)
ness
(female) (2)
Max. 1 Ω
(female) (3)

2. Disconnect connectors ECM1 J1 and AFT1_PFUEL, and connect T adapter to either
3
ness
AFT1_PFUEL (female) (3)

2. Disconnect connectors ECM1 J1 and AFT1_PFUEL, and connect T adapter to the
4
ness
pin (57)

Defective Fuel doser pres- 2. Insert T-adapter into connector AFT1_PFUEL.
sure sensor
Voltage Between AFT1_PFUEL (3) and (2) 0.5 to 4.5 V
40-442 HD465-8, HD605-8


Circuit diagram related to fuel doser pressure sensor
HD465-8, HD605-8 40-443


Action level Failure code Crankcase Pressure Sensor In Range Error
Failure
Details of fail-
The shown value of the output from the crankcase pressure sensor is out of the normal range.
ure
Function of
None in particular
Controller
Effect on the
None in particular
machine
48401)
Related infor-
q Pressure detected by the crankcase pressure sensor can be checked by the monitoring function. (Code:
mation
48400)
q This code appears if sensor value is abnormal when the start switch is turned to the ON position.

2

sure sensor
40-444 HD465-8, HD605-8

HD465-8, HD605-8 40-445


Action level Failure code Fuel Doser Solenoid 1 Servo Error
Failure
Details of fail- Pressure in the fuel doser pressure sensor is lower than the specified value when the fuel doser solenoid
ure valve 1 (shut off valve) is ON.
Function of
Controller
q If the failure code [CA1923], [CA1924], or [CA1925] is shown, the fuel doser solenoid valve 1 system
may be defective. Troubleshoot for [CA1923], [CA1924], or [CA1925] first.
q If the failure code [CA2732] or [CA2733] is shown, the fuel doser solenoid valve 2 system may be de-
fective. Troubleshoot for [CA2732] or [CA2733].
q If the failure code [CA1927] or [CA1928] is shown, the fuel doser pressure sensor system may be de-
fective. Troubleshoot for [CA1927] or [CA1928] first.
Related infor- q If the failure code [CA559] is shown, Fuel supply pump system may be defective. Troubleshoot for
mation [CA559] first.
q If the failure code [CA2265] or [CA2266] is shown, fuel feed pump system may be defective. Trouble-
shoot for [CA2265] or [CA2266] first.
q How to remove the failure code
Procedure: Turn the start switch from the OFF to the ON position to start the engine. When the failure
code is removed after the engine operates at low idle for approximately 3 minutes, the repair is complet-
ed.
Procedure: Start the engine. (Examine the condition for 3 minutes.)

connector
2 Obstructed fuel filter Inspect the fuel filter for obstructions.
Check if No.8 in fuse box BT2 is blown out.
Defective fuse for fuel feed
3
pump
REMARK
If blown out, perform troubleshooting for ground fault in wiring harness.
40-446 HD465-8, HD605-8

1. Turn starting switch to OFF position.

2. Check that system operating lamp is not lit, and then turn battery disconnect switch to
OFF position.
3. Disconnect connector EPTS, and connect T-adapter to female side.
4. Turn the battery disconnect switch to ON position.
5. Turn starting switch to ON position.
Between EPTS (female) (3) and (10) 20 to 30 V
Voltage
4
ness 1. Turn starting switch to OFF position.
OFF position.
Between EPTS (female) (3) and BT2-16 Max. 1 Ω
Between EPTS (female) (3) and (4) Max. 1 Ω
Resistance
Between EPTS (female) (9) and ground Max. 1 Ω

Ground fault in wiring har- OFF position.
5 3. Disconnect connector EPTS, and connect T-adapter to female side.
ness
4. Remove fuse No.8 in fuse box BT2.
Resistance Between ground and EPTS (female) (3) Min. 1 MΩ
1. Turn the starting switch to OFF position.

2. Loosen the fuel tube joint bolt (JB).
3. Tilt the switch for the fuel feed pump to ON position while the starting switch is in OFF
position.
Defective fuel feed pump k Fuel may spurt out. So be careful.
6
system
4. Set the switch for the fuel feed pump to OFF position and finish the test.
If fuel does not come out from the joint bolt (JB) of fuel tube, perform troubleshooting for
"FUEL FEED PUMP DOES NOT OPERATE OR DOES NOT STOP AUTOMATICALLY"
in E mode.

2. Disconnect fuel supply line -A (2A) from fuel doser -A (1A).
Defective Fuel doser pres-
7 4. See RELATED INFORMATION TO TROUBLESHOOT to show the dosing fuel pres-
sure sensor
sure and ambient pressure at the same time on the machine monitor.
If the fuel doser pressure and ambient pressure are different, the dosing fuel pressure
sensor is defective.
8 Replace fuel doser solenoid valve 1-A (shut-off valve).
noid valve 1
Start the engine, and leave it for approximately 3 minutes. (Implementation of related
information, "Method of clearing failure code".)
9 Defective engine controller If this failure code is still displayed and no failure is found by preceding checks, engine
controller is defective. (In case of an internal defect, troubleshooting is impossible as an
assembly. Replace whole assembly.)
HD465-8, HD605-8 40-447


1A. Fuel doser-A
1B. Fuel doser-B
a: From fuel pump-A
b: From fuel pump-B
c: Fuel return
tor
Circuit diagram related to the fuel doser solenoid valve
40-448 HD465-8, HD605-8

Circuit diagram related to the electrical fuel feed pump switch
HD465-8, HD605-8 40-449


Action level Failure code Fuel Doser Open Error or Short Error
Failure
Details of fail-
Short circuit or open circuit occurs in fuel doser circuit.
ure
Function of
Controller
47601)
q Pressure detected by the dosing fuel pressure sensor can be checked by the monitoring function.
(Code: 47600)
q Disable regeneration control is removed when you turn the start switch to the OFF position.
Related infor-
mation
NOTICE
q After you investigate the cause of the problem and complete the repair, perform Loaded Diag-

connector

2. Disconnect connector AFT1_HC_INJ, and connect T adapter to the male side.
Defective fuel doser injec-
2
tor Between AFT1_HC_INJ (male) (1) and (2) 0.5 to 2 Ω
Resistance
Between AFT1_HC_INJ (male) (1) and ground Min. 1 MΩ

2. Disconnect connectors ECM1 J1 and AFT1_HC_INJ, and connect T adapter to each
female side.
3 Between ECM1 J1 (female) (5) and AFT1_HC_INJ
ness Max. 1 Ω
(female) (1)
Resistance
Between ECM1 J1 (female) (29) and AFT1_HC_INJ
Max. 1 Ω
(female) (2)

2. Disconnect connectors ECM1 J1 and AFT1_HC_INJ, and connect T adapter to either
4
ness
AFT1_HC_INJ (female) (1)

Hot short circuit in wiring 2. Disconnect connector AFT1_HC_INJ, and connect T adapter to the female side.
harness
Voltage Between AFT1_HC_INJ (female) (2) and ground Max. 3 V
40-450 HD465-8, HD605-8


2. Disconnect connectors ECM1 J1 and AFT1_HC_INJ, and connect T adapter to the
6
ness
pin (5)
Loaded Diagnostics Operation To Remove Failure Code

Use the procedures that follow to make sure that the repair is complete.
Make sure that the failure code is not shown.
2. Turn the starting switch from OFF to ON position.
3. Start the engine, and perform Active Regeneration for Service.
4. When failure code [CA1977] is removed, stop the Active Regeneration for Service.
Circuit diagram related to fuel doser (injector)
HD465-8, HD605-8 40-451


Action level Failure code KDPF Differential Pressure Low Error
Failure
Details of fail-
Signal voltage from KDPF differential pressure sensor is lower than specified value.
ure
q Closes EGR valve.
Controller q Stops regeneration control.
Effect on the
machine
q If the failure code [CA1879], [CA1881], or [CA1883] is shown, KDPF differential pressure sensor system
may be defective. Troubleshoot for [CA1879], [CA1881], or [CA1883].
q To start the engine again, wait until the system operation lamp goes off after you turn the start switch to
Related infor- the OFF position. Then turn the start switch to the ON position.
mation NOTICE
q This failure code requires the machine operation for clearing the failure code. After investigating
the cause of the problem and completing the repair, perform Loaded Diagnostics Operation To
Clear Failure Code to make sure the failure code is cleared.
1. Turn the start switch to the OFF position, and then turn it to the ON position again.
2. Determine if a failure code other than [CA1993] appears.
3. Start the engine, accelerate from low idle speed to high idle speed twice, and then
1 KCSF Abnormality 1 keep the engine at high idle speed for 5 seconds. Examine the exhaust gas color out
of the exhaust pipe when you suddenly accelerate and at high idle.
4. If black smoke comes out of the exhaust pipe, the KCSF is defective. Inspect the
KCSF, for damages, or contamination by unwanted materials, and repair as neces-
sary.

3. Inspect the KDPF differential pressure sensor pipe for cracks and damage.
Defective KDPF differential 5. Perform Loaded Diagnostics Operation To remove the failure code.
2
REMARK
1. Remove KDPF and then remove KCSF to examine the filter in the KCSF. Inspect for
3 KCSF Abnormality 2 damage or contamination by unwanted materials, and then repair the filter.
2. Perform Loaded Diagnostics Operation To remove the failure code.

(Make sure this failure code is not shown after this procedure.)
40-452 HD465-8, HD605-8

REMARK
turned to the ON position.
2. Turn the start switch to OFF position to stop the engine controller.
5. Stall torque converter continuously for approximately 1 minute as described below with accelerator pedal open position
100%.
1) Make sure the park brake switch is set to the "PARK" position. Be sure to set the gear shift lever to the "D" position
2) Gradually depress the accelerator pedal with the brake pedal depressed to stall the torque converter.
NOTICE
REMARK
30100)
REMARK
q If this failure code is not removed, perform previous steps 4 and 5, three times.
HD465-8, HD605-8 40-453


Action level Failure code Throttle Sensor Supply Voltage High Error
Failure
Details of fail-
High voltage is generated in the throttle sensor power supply (5 V) circuit.
ure
Action of con- Set the accelerator pedal position 0 % with the accelerator pedal OFF and the specified value with the
troller accelerator pedal ON, and run the engine.
Effect on the
machine

connector

2. Disconnect connector AS1.
Defective throttle sensor
2
(accelerator pedal) If this failure code is not shown, the throttle sensor is defective.
REMARK

2. Disconnect connector AS1, and connect T adapter to the female side.
3
harness
4.75 to 5.25
Voltage Between AS1 (female) (1) and ground
V

4
ness
pin (9)
40-454 HD465-8, HD605-8

HD465-8, HD605-8 40-455


Action level Failure code Throttle Sensor Supply Voltage Low Error
Failure
Details of fail-
Low voltage is generated in the throttle sensor power supply (5 V) circuit.
ure
Action of con- Set the accelerator pedal position 0 % with the accelerator pedal OFF and the specified value with the
troller accelerator pedal ON, and run the engine.
Effect on the
machine

connector

2. Disconnect connector AS1.
Defective throttle sensor
2
(accelerator pedal) If this failure code is not shown, the throttle sensor is defective.
REMARK

2. Disconnect connectors ECM1 J2 and AS1, and connect T adapter to either female
ness
Between ground and ECM1 J2 (female) (9) or AS1
(female) (1)

4
ness
pin (9)
40-456 HD465-8, HD605-8

HD465-8, HD605-8 40-457


Action level Failure code Common Rail Pressure Low Error 2
Failure
Details of fail- No-pressure error is sensed in the supply pump. (Pressure lower than specified pressure continues for a
ure long time: Level 2.)
Effect on the
machine
36401 (V))
Related infor- q Common rail pressure detected by the common rail pressure sensor can be checked by the monitoring
mation function. (Code: 36400 (MPa))

1 Fuel used may be out of specification, examine it.
specification
For details to troubleshoot, see Note 1, How to Test the Low-pressure Circuit Devices.
To test the fuel low-pressure circuit pressure, see TEST AND ADJUST, "FUEL PRES-
Defective fuel low-pres- SURE TEST".
2
sure circuit device
Fuel low-pressure circuit pressure (high idle
or load equivalent to rated operation) 0.15 to 0.30 MPa {1.5 to 3.0 kg/cm2}
3 Clogged filter, or strainer For details to troubleshoot, see Note 2, How to Test the Low-pressure Circuit Devices.
connector

5
Resistance

6
ness
Resistance

harness

8
tor)
40-458 HD465-8, HD605-8


9
Resistance

10
ness
Resistance

harness

12
tor)
Defective common rail Inspect for damage of the wiring harness because the common rail pressure sensor may
13
pressure sensor be defective.
To test the pressure limiter leakage quantity, see TEST AND ADJUST, "FUEL RETURN
RATE AND LEAKAGE TEST".
14 Defective pressure limiter
Pressure limiter leakage quantity (speed in
Max. 10 cc/min
rated operation or equivalent (stall load))
To measure the limit return rate (spill) from injector, see TEST AND ADJUST, "FUEL
RETURN RATE AND LEAKAGE TEST".
1600 rpm 960 cc/min
15 Defective injector 1700 rpm 1020 cc/min

Limit return
Speed in rated operation or
rate (spill) 1800 rpm 1080 cc/min
equivalent (stall load)
from injector
To test if either the supply pump A or supply pump B is defective, see TEST AND
ADJUST, "SUPPLY PUMP TEST".
How to Test the Low-pressure Circuit Devices

<Using the check sheet>
Perform the above troubleshooting, and also record the results of the check sheet, using the attached "Check Sheet for
No-pressure Error".
Note 1: For the low pressure circuit device, investigate the following items.
q Fuel level
q Clogged fuel tank breather
q Stuck or worn feed pump or clogged filter.
q Leakage or obstruction of low pressure fuel piping
q Malfunction of the bypass valve (See the figure below.)
q Obstructed fuel filter
q Fuel is mixed into the oil filter (fuel leakage in the head cover)
HD465-8, HD605-8 40-459

Position of the overflow valve (1), bypass valve (2), and fuel inlet joint (3)
Overflow valve (1): Spring is seen through each holes.

Bypass valve (2): Spring is seen through the hole on the nut side.
Fuel inlet joint (3): Gauze filter is seen through each hole.
Note 2: Perform the following to check, clean, and replace the filters and strainers.
1. Gauze filter: Disassemble and check and clean if clogged.
2. Strainer on upstream side of gauze filter: If gauze filter is clogged, clean upstream strainer as well.
3. Fuel filter: If the failure is not solved by performing the steps in 1 and 2 above, replace the fuel filter.
Check Sheet for No-pressure Error
Model Work No.
Model and serial No. Date inspected
Engine SAA6D170E-7 Service meter
Engine serial No. Name
A. Inspect visually Go No
1 External fuel leaks
2 Clogged fuel tank breather
40-460 HD465-8, HD605-8

No
B. Inspect by the machine monitor (Failure record, monitor information, cylinder Cutout Mode Operation) Good
good
3 Inspect the failure code
Inspect the monitor information
Code Item shown Testing conditions Unit Good
Low idle r/min 750 (±50)
1002 Engine speed High idle r/min 2270 (±50)
Torque converter stall r/min 1931 (±100)
Accelerator pedal Low idle % 0

31701
position High idle % 100
4 Inject Fueling Com-
18600 mand (Unit of Torque converter stall mg/st - - -
weight)
Rail Pressure Com-
mand
Common rail pres-
sure
36500 Boost pressure Torque converter stall kPa - - -
Engine coolant tem-
4107 Low idle °C - - -
perature
Check of Cylinder Cutout Mode Operation (engine speed)
Func- Standard value Measured No
Cutout cylinder Testing conditions Unit Good
tion for new machine value good
Set No. 2 cylinder Low idle r/min - - -
5
cutout
to No. 3 cylinder Low idle r/min - - -
each No. 4 cylinder Low idle r/min - - -
cylin-
der No. 5 cylinder Low idle r/min - - -

C. Check of fuel circuit pressure Testing conditions Unit Good
MPa 0.15 to 0.30
6 Fuel pressure High idle
{kg/cm2} {1.5 to 3.0}
No
D. Check of strainer and filter Good
good
7 Visual check of strainer
8 Visual check of gauze filter
9 Visual check of fuel filter
10 Visual check of bypass valve
HD465-8, HD605-8 40-461


E. Check of leakage and return rate Test conditions Unit Good
Leakage from the pressure Load equivalent to rated opera-
11 cc/min Max. 10
limiter tion (at stall)
Torque converter stall: 1600
cc/min 960
rpm
cc/min 1020
rpm
Torque converter stall: 1800 Fan speed:
12 Return rate from injector cc/min 1080
rpm Return rate:
cc/min 1140
rpm
cc/min 1200
rpm
Circuit diagram related to fuel system
40-462 HD465-8, HD605-8


Action level Failure code Fuel Feed Pump Open Error
Failure
Details of fail-
The signal circuit of the Fuel feed pump is open (when the controller operates the pump timer switch).
ure
Function of
None in particular
Controller
Effect on the q While you bleed the air, the engine becomes hard to start.
machine q Defective KDPF regeneration.
q This failure code is sensed only when the feed pump is OFF.
Related infor-
mation

connector

Open circuit in wiring har- 2. Disconnect connectors ECM1 J1 and EPTS, and connect T adapter to each female
2 side.
ness
Resistance Between ECM1 J1 (female) (7) and EPTS (female) (5) Max. 1 Ω

Hot short circuit in wiring 2. Insert T adapter into the connector EPTS.
harness
Voltage Between EPTS (5) and ground Max. 1 V
Fuel feed pump operates during the pressure test immediately after you start the engine.
1. Turn the start switch to the OFF position, and stop the engine controller.
2. Insert T adapter into the connector EPTS.
Defective pump timer 4. Start the engine. (Pump timer switch is actuated only immediately after you start the
4 engine.)
switch
When the pump timer switch
20 to 30 V
Between EPTS (5) and is actuated
Voltage
ground When the pump timer switch
Max. 1 V
is stopped
HD465-8, HD605-8 40-463

Circuit diagram related to electric fuel feed pump switch
40-464 HD465-8, HD605-8


Action level Failure code Fuel Feed Pump Short Error
Failure
Details of fail- The signal circuit of the Fuel Feed pump has a short circuit (when the controller operates the pump timer
ure switch).
Function of
None in particular
Controller
Effect on the q While you bleed the air, the engine becomes hard to start.
q This failure code is detected only when the feed pump is ON.
Related infor- q After the repair is completed, check that the failure code is cleared by the following procedure.
mation 1. Turn the start switch to the OFF position, and stop the engine controller.

connector
2. Disconnect the connector EPTS.
Defective pump timer 4. Start the engine.
2
switch
If this failure code is not shown, the throttle sensor is defective.
REMARK

2. Disconnect connectors ECM1 J1 and EPTS, and connect T adapter to each female
3
ness
Between ground and ECM1 J1 (female) (7) or EPTS
(female) (5)
HD465-8, HD605-8 40-465

Circuit diagram related to electric fuel feed pump switch
40-466 HD465-8, HD605-8


Action level Failure code EGR Valve Position Sensor High Error
Failure
Details of fail-
High voltage is generated in signal circuit of EGR valve lift sensor.
ure
Function of
q Closes EGR valve.
Controller
Effect on the
machine
q Signal voltage from the EGR valve lift sensor can be checked by the monitoring function. (Code: 18101).
q Position (mm) detected by the EGR valve lift sensor can be checked by the monitoring function. (Code:
Related infor-
18100)
mation

connector

Open circuit in wiring har- 2. Disconnect connectors ECM1 J1 and SEGR, and connect T adapter to each female
2 side.
ness
Resistance Between ECM1 J1 (female) (57) and SEGR (female) (2) Max. 1 Ω

Hot short circuit in wiring 2. Disconnect connector SEGR, and connect T-adapter to either female side.
harness
Voltage Between SEGR (female) (3) or SEGR (female) (4) and (2) Max. 1 V

2. Disconnect connectors ECM1 J1 and SEGR, and connect T adapter to either female
4
ness Between ECM J1 (female) (81) and (88), between SEGR
Resistance (female) (1) and (3), or between SEGR (female) (1) and Min. 1 MΩ
(4)

Defective EGR valve lift 2. Insert T adapter into connector SEGR.
sensor
Voltage Between SEGR (3) and (2) 1.0 to 4.0 V
HD465-8, HD605-8 40-467

Circuit diagram related to EGR valve lift sensor
40-468 HD465-8, HD605-8


Action level Failure code EGR Valve Position Sensor Low Error
Failure
Details of fail-
Low voltage is generated in signal circuit of EGR valve lift sensor.
ure
Function of
q Closes EGR valve.
Controller
Effect on the
machine
q Signal voltage from the EGR valve lift sensor can be checked by the monitoring function. (Code: 18101).
q Position (mm) detected by the EGR valve lift sensor can be checked by the monitoring function. (Code:
Related infor-
18100)
mation

connector

2. Disconnect connectors ECM1 J1 and SEGR, and connect T adapter to each female
side.
Open circuit in wiring har- Between ECM1 J1 (female) (81) and SEGR (female) (1) Max. 1 Ω
2
ness
Between ECM1 J1 (female) (57) and SEGR (female) (2) Max. 1 Ω
Resistance
Between ECM1 J1 (female) (88) and SEGR (female) (3),
Max. 1 Ω
(4)

3
ness
Between ground and ECM1 J1 (female) (88) or SEGR
(female) (3)

4
ness
Between J1 (female) (88) and (57), or between SEGR

sensor
HD465-8, HD605-8 40-469

Circuit diagram related to EGR valve lift sensor
40-470 HD465-8, HD605-8


Action level Failure code EGR Valve Solenoid Open Circuit Error
Failure
Details of fail-
Open circuit occurs in EGR valve solenoid drive circuit.
ure
Function of
q Closes EGR valve.
Controller
Effect on the
machine
q Signal current to the EGR valve solenoid can be checked by the monitoring function. (Code: 48600)
Related infor-
mation

connector

2. Disconnect connector EGR-SOL, and connect T-adapter to male side.
Defective EGR valve sole-
2
noid Between EGR-SOL (male) (1) and (2) 5 to 10 Ω
Resistance
Between EGR-SOL (male) (1) and ground Min. 1 MΩ

Defective circuit related to 2. Disconnect connector EGR-SOL, and connect T-adapter to female side.
EGR valve solenoid
Voltage Between EGR-SOL (female) (1) and (2) Max. 3 V

2. Disconnect connectors ECM1 J1 and EGR-SOL, and connect T-adapter to each
female side.
4 Between ECM1 J1 (female) (13) and EGR-SOL (female)
ness Max. 1 Ω
(1)
Resistance
Between ECM1 J1 (female) (76) and EGR-SOL (female)
Max. 1 Ω
(2)

2. Disconnect connectors ECM1 J1 and EGR-SOL, and connect T-adapter to either
female side.
5 Between ground and ECM1 J1 (female) (13) or EGR-SOL
ness Min. 1 MΩ
(female) (1)
Resistance
Between ground and ECM1 J1 (female) (76) or EGR-SOL
Min. 1 MΩ
(female) (2)

6 female side.
ness
EGR-SOL (female) (1) and (2)
HD465-8, HD605-8 40-471

Circuit diagram related to EGR valve solenoid
40-472 HD465-8, HD605-8


Action level Failure code EGR Valve Solenoid Short Circuit Error
Failure
Details of fail-
EGR valve solenoid drive circuit has short circuit.
ure
Function of
q Closes EGR valve.
Controller
Effect on the
machine
q Signal current to the EGR valve solenoid can be checked by the monitoring function. (Code: 48600)
Related infor-
mation

connector

2. Disconnect connector EGR-SOL, and connect T-adapter to male side.
Defective EGR valve sole-
2
noid Between EGR-SOL (male) (1) and (2) 5 to 10 Ω
Resistance
Between EGR-SOL (male) (1) and ground Min. 1 MΩ

Hot short circuit in wiring 2. Disconnect connector EGR-SOL, and connect T-adapter to female side.
harness
Voltage Between EGR-SOL (female) (1) and (2) Max. 3 V
HD465-8, HD605-8 40-473

Circuit diagram related to EGR valve solenoid
40-474 HD465-8, HD605-8


Action level Failure code EGR Valve Servo Error
Failure
Details of fail- EGR valve malfunctions. (Value from EGR valve position sensor is different from the value of EGR valve
ure open command.)
Function of
q Closes EGR valve.
Controller
Effect on the
machine
q Position of the EGR valve can be checked by the monitoring function. (Code: 18100 EGR valve position
(mm))
Related infor- q After this failure code is removed, turn the start switch to OFF to cancel the engine power derate. (Re-
mation moval of the failure code does not cancel the derate.)

Defective EGR valve oper- To test EGR valve operation pressure, see TEST AND ADJUST, "EGR VALVE AND
1
ation oil pressure VGT OIL PRESSURE TEST".
q To test the engine oil pressure, see TEST AND ADJUST, "TEST ENGINE OIL PRES-
Defective engine oil pres- SURE".
2
sure system q If the engine oil pressure is not normal, Troubleshoot (S mode), Engine Oil Pressure
Low.
Defective oil pump for
3 Perform checks since the oil pump and relief valve for EGR circuit may be defective.
EGR valve
Defective hydraulic piping
4 Perform checks since the hydraulic piping for EGR valve circuit may be defective.
for EGR valve
Defective hydraulic return
5 Perform checks since the hydraulic return piping for EGR valve circuit may be defective.
piping for EGR valve
q Perform checks since EGR valve may be mechanically defective.
6 Defective EGR valve
q Check specifically that there is no foreign material in oil inlet and outlet of EGR valve.
connector

2. Disconnect connectors ECM1 J1 and SEGR, and connect T adapter to each female
side.
Open circuit in wiring har- Between ECM1 J1 (female) (81) and SEGR (female) (1) Max. 1 Ω
8
ness
Between ECM1 J1 (female) (57) and SEGR (female) (2) Max. 1 Ω
Resistance
Between ECM1 J1 (female) (88) and SEGR (female) (3),
Max. 1 Ω
(4)

9
ness
Between ground and ECM1 J1 (female) (88) or SEGR
(female) (3)
HD465-8, HD605-8 40-475


Hot short circuit in wiring 2. Disconnect connector SEGR, and connect T-adapter to either female side.
harness
Voltage Between SEGR (female) (3) or SEGR (female) (4) and (2) Max. 1 V

side.
Short circuit in wiring har- Between ECM J1 (female) (81) and (88), between SEGR
11
ness (female) (1) and (3), or between SEGR (female) (1) and Min. 1 MΩ
Resistance (4)
Between J1 (female) (88) and (57), or between SEGR
Min. 1 MΩ

sensor
Circuit diagram related to EGR system
40-476 HD465-8, HD605-8


Action level Failure code VGT Position Sensor High Error
Failure
Details of fail-
High voltage is generated in VGT position sensor signal circuit.
ure
Function of
Controller
Effect on the
machine
q Signal voltage from the VGT position sensor can be checked by the monitoring function. (Code: 48701)
q Position (mm) detected by the VGT position sensor can be checked by the monitoring function. (Code:
Related infor-
48700)
mation

connector

Open circuit in wiring har- 2. Disconnect connectors ECM1 J1 and SVGT, and connect T adapter to each female
2 side.
ness
Resistance Between ECM1 J1 (female) (57) and SVGT (female) (B) Max. 1 Ω

Hot short circuit in wiring 2. Disconnect connector SVGT, and connect T adapter to the female side.
harness
Voltage Between SVGT (female) (C) and (B) Max. 1 V

2. Disconnect connectors ECM1 J1 and SVGT, and connect T adapter to either female
4
ness
SVGT (female) (A) and (C)

Defective VGT position 2. Insert T adapter into connector SVGT.
sensor
Voltage Between SVGT (C) and (B) 1.0 to 4.0 V
HD465-8, HD605-8 40-477

Circuit diagram related to VGT position sensor
40-478 HD465-8, HD605-8


Action level Failure code VGT Position Sensor Low Error
Failure
Details of fail-
Low voltage is generated in VGT position sensor signal circuit.
ure
Function of
Controller
Effect on the
machine
q Signal voltage from the VGT position sensor can be checked by the monitoring function. (Code: 48701)
q Position (mm) detected by the VGT position sensor can be checked by the monitoring function. (Code:
Related infor-
48700)
mation

connector

2. Disconnect connectors ECM1 J1 and SVGT, and connect T adapter to each female
side.
2 Between ECM1 J1 (female) (81) and SVGT (female) (A) Max. 1 Ω
ness
Between ECM1 J1 (female) (67) and SVGT (female) (C) Max. 1 Ω

3
ness
Between ground and ECM1 J1 (female) (67) or SVGT
(female) (C)

4
ness
SVGT (female) (B) and (C)

sensor
HD465-8, HD605-8 40-479

40-480 HD465-8, HD605-8


Action level Failure code VGT Solenoid Open Circuit Error
Failure
Details of fail-
Open circuit occurs in VGT solenoid drive circuit.
ure
Function of
Controller
Effect on the
machine
q Signal current to the VGT solenoid can be checked by the monitoring function. (Code: 48800)
Related infor-
mation

connector

2. Disconnect connector VGT-SOL, and connect T-adapter to male side.
2 Defective VGT Solenoid
Between VGT-SOL (male) (1) and (2) 5 to 10 Ω
Resistance
Between VGT-SOL (male) (1) and ground Min. 1 MΩ

2. Disconnect connector VGT-SOL, and connect T-adapter to female side.
Defective circuit related to 3. Turn the starting switch to ON position.
3
VGT solenoid
Voltage Between VGT-SOL (female) (1) and (2) Max. 3 V

2. Disconnect connectors ECM1 J2 and VGT-SOL, and connect T-adapter to each
female side.
4
ness Between ECM1 J2 (female) (80) and VGT-SOL (female)
Max. 1 Ω
Resistance (1)
Between ECM1 J2 (female) (2) and VGT-SOL (female) (2) Max. 1 Ω

female side.
5 Between ground and ECM J2 (female) (80) or VGT-SOL
ness Min. 1 MΩ
(female) (1)
Resistance
Between ground and ECM1 J2 (female) (2) or VGT-SOL
Min. 1 MΩ
(female) (2)

6 female side.
ness
VGT-SOL (female) (1) and (2)
HD465-8, HD605-8 40-481

Circuit diagram related to VGT valve solenoid
40-482 HD465-8, HD605-8


Action level Failure code VGT Solenoid Short Circuit Error
Failure
Details of fail-
VGT solenoid drive circuit has short circuit.
ure
Function of
Controller
Phenomenon
on machine
q Signal current to the VGT solenoid can be checked by the monitoring function. (Code: 48800)
Related infor-
mation

connector

2. Disconnect connector VGT-SOL, and connect T-adapter to male side.
2 Defective VGT Solenoid
Between VGT-SOL (male) (1) and (2) 5 to 10 Ω
Resistance
Between VGT-SOL (male) (1) and ground Min. 1 MΩ

Hot short circuit in wiring 2. Disconnect connector VGT-SOL, and connect T-adapter to female side.
harness
Voltage Between VGT-SOL (female) (1) and (2) Max. 3 V
HD465-8, HD605-8 40-483

Circuit diagram related to VGT valve solenoid
40-484 HD465-8, HD605-8


Action level Failure code VGT Servo Error
Failure
Details of fail-
VGT servo error occurs. (Value from the VGT position sensor differs from the VGT open value.)
ure
Function of
Controller
Effect on the
machine

Insufficient VGT drive To test VGT drive pressure, see TEST AND ADJUST, "EGR VALVE AND VGT OIL
1
pressure PRESSURE TEST".
q To test the engine oil pressure, see TEST AND ADJUST, "TEST ENGINE OIL PRES-
Defective engine oil pres- SURE".
2
sure system q If the engine oil pressure is not normal, Troubleshoot (S mode), Engine Oil Pressure
Low.
3 Defective oil pump for VGT Perform checks since the oil pump and relief valve for VGT circuit may be defective.
Defective hydraulic piping
4 Perform checks since the hydraulic piping for VGT circuit may be defective.
for VGT
Defective hydraulic return
5 Perform checks since the hydraulic return piping for VGT circuit may be defective.
piping for VGT
q Inspect the VGT for mechanical failure.
q Make sure that there is no unwanted material in the oil inlet of VGT servo.
q Perform the manual stationary regeneration. At this time, if KDOC inlet temperature
remains at approximately 250 °C or below and VGT solenoid current remains at ap-
6 Defective VGT proximately 1000 mA, VGT is defective. (Approximate time taken for manual station-
ary regeneration depends on accumulation of soot. See the failure code [CB2639].)
REMARK
q KDOC inlet temperature can be checked by the monitoring function. (Code: 47300)
q VGT solenoid current can be checked by the monitoring function. (Code: 48800)
connector

2. Disconnect connectors ECM1 J1 and SVGT, and connect T adapter to each female
side.
8 Between ECM1 J1 (female) (81) and SVGT (female) (A) Max. 1 Ω
ness
Between ECM1 J1 (female) (67) and SVGT (female) (C) Max. 1 Ω
HD465-8, HD605-8 40-485


9
ness
Between ground and ECM1 J1 (female) (67) or SVGT
(female) (C)

Hot short circuit in wiring 2. Disconnect connector SVGT, and connect T adapter to the female side.
harness
Voltage Between SVGT (female) (C) and (B) Max. 1 V

side.
ness Min. 1 MΩ
SVGT (female) (A) and (C)
Resistance
Min. 1 MΩ
SVGT (female) (B) and (C)

sensor
40-486 HD465-8, HD605-8


Action level Failure code Intake Air Heater Relay Open Circuit Error
Failure
Details of fail-
Short circuit is sensed in the preheat relay operation circuit (primary side).
ure
Function of
None in particular
Controller
Effect on the Intake air heater does not work in automatic preheat mode (the engine is hard to start and emits white
machine smoke at low temperature).
q This failure code is sensed only when the relay is OFF.
Related infor-
mation
Procedure: Turn the start switch to the ON position (engine coolant temperature: -4 °C and higher).

connector

2 Defective preheating relay 2. Disconnect connector R19, and connect T adapter to the male side.
Resistance Between R19 (male) (1) and (2) 200 to 400 Ω

2. Disconnect connectors ECM1 J2 and R19, and connect T adapter to each female
3
ness
Between ECM1 J2 (female) (75) and R19 (female) (1) Max. 1 Ω
Resistance
Between ECM1 J2 (female) (61) and R19 (female) (2) Max. 1 Ω
Perform in conditions where preheat does not work (engine coolant: -4 °C or higher).
4
harness 3. Turn the start switch to the ON position.
Voltage Between ECM1 J2 (75) and (61) Max. 1 V
HD465-8, HD605-8 40-487

Circuit diagram related to intake air heater relay
40-488 HD465-8, HD605-8


Action level Failure code Intake Air Heater Relay Short Circuit Error
Failure
Details of fail-
Short circuit is sensed in air intake heater relay operation circuit (primary side).
ure
Function of
None in particular
Controller
Effect on the Intake air heater does not work in automatic preheat mode (the engine is hard to start and emits white
machine smoke at low temperature).
q This failure code is sensed only when the relay is ON.
Related infor-
mation
Procedure: Turn the start switch to the ON position (engine coolant temperature: -5 °C or less).

connector

2 Defective preheating relay 2. Disconnect connector R19, and connect T adapter to the male side.
Resistance Between R19 (male) (1) and (2) 200 to 400 Ω

2. Disconnect connectors ECM1 J2 and relay R19, and connect T adapter to either
3
ness
Between ground and ECM1 J2 (female) (75) or R19
(female) (1)

2. Disconnect connector ECM1 J2 and relay R19, and connect T adapter to the female
4
ness
pin (75)
HD465-8, HD605-8 40-489

Circuit diagram related to intake air heater relay
40-490 HD465-8, HD605-8


Action level Failure code KDOC Face Plugging
Failure
KDOC face is plugged.

q The KDOC is not as efficient because of surface contamination from the conditions of operation. Clean
Details of fail-
the KDOC.
ure
q KDOC deterioration because of high temperature or not as efficient because of damage or contamina-
tion. Replace KDOC with a new or used one.)
Procedure of
controller
Machine Event None in particular
k Exhaust connector on turbocharger, KDOC, and KDPF become hot (Minimum. 500°C). Be careful
not to become burned.
q If the failure code [CA238*] is shown, VGT may be defective. Troubleshoot for it first.
q If the failure code [CA227*] or [CA23**] is shown, EGR valve may be defective. Troubleshoot for it first.
q If KDOC of KDPF is replaced, perform the set procedure again after the KDOC is changed, then the
repair is completed.
q When the soot accumulation level is 3 or lower, manual stationary regeneration from Active Regenera-
Related infor- tion for service is performed.
mation q If the KDOC is not efficient, failure code [AQ10N3] is shown after failure code [CA2637] is shown again
and again. After that, if the KDOC is not efficient, failure code [CA1691] is shown, may indicate defective
regeneration.
q How to clear the failure code
Start the engine, perform warm-up operation, and operate the machine in normal work for approximately
3 hours. (The time required to clear codes will reduce with high exhaust temperature conditions.)
NOTICE
Operate the machine for approximately 3 hours, and make sure that this failure code is removed.
No. Cause Procedures, test location, measured standards and remarks.
Incorrect turbocharger 1. Remove the turbocharger exhaust connector.

1
exhaust connector 2. Inspect for oil or fuel stuck to the inner side of the turbocharger exhaust connector.
Defective exhaust connec- Examine the exhaust system between the turbocharger and KDPF for damages to con-
2
tor or pipe to KDPF nectors, pipes, or loose connections.
Quickly accelerate the engine from low to high idle twice, and then keep the engine at
high idle speed for 5 seconds.
REMARK
To test the exhaust gas color, See TEST AND ADJUST, "TEST EXHAUST GAS
COLOR".
3 Incorrect exhaust gas color
If excess black smoke is seen at high idle or when the engine accelerates, perform "KDPF
GETS CLOGGED IN A SHORT TIME".
REMARK
If black smoke comes out when the engine accelerates, but disappears at high idle, there
is no problem.
HD465-8, HD605-8 40-491

1. Remove KDPF.
2. Remove KDOC.
3. Apply air through the KDOC outlet, and clean the surface on the inner side of the
KDOC.
4. Inspect the inner side of the KDOC for cracks.
5. If there is a crack or damage to the KDOC , the KDOC is defective, replace KDOC.
Defective KDOC
6. Perform KDPF Memory Reset after installation or replacement of KDOC or KDPF. For
4 (unwanted material, crack,
details, see TEST AND ADJUST, "SERVICE MODE" and "PROCEDURE TO
damage)
OPERATE THE TEST MENU (KDPF MEMORY RESET)" under "SET AND
REMARK
The failure codes [CA1691] and [CA2637] do not appear after the KDPF Memory setting
is performed. At this point, the procedure to prevent fuel dose injection is stopped, which
was necessary when this failure code was shown.
When the KDOC is not replaced.
2. Record the initial conditions of the KDOC inlet and outlet temperature sensors, and
temperature during manual stationary regeneration. Inspect for normal KDOC outlet
sensor temperature. (See RELATED INFORMATION ON TROUBLESHOOTING.)
4. Secure the machine in a safe area.
5. From the Service Menu in the machine monitor, display Diagnostic Tests screen, open
(Manual stationary regeneration finishes in approximately 40 minutes.)
KDOC function)
does not appear, perform KDPF Memory Reset and complete the troubleshooting.
8. If failure code [CA2637] is shown after you complete the manual stationary regenera-
tion, KDOC is defective. (Function of KDOC is lowered. Replace the KDOC.)
ADJUST, "SERVICE MODE" and "PROCEDURE TO OPERATE THE TEST MENU
(KDPF MEMORY RESET)" under "SET AND OPERATE OF MACHINE MONITOR".
REMARK
The failure codes [CA1691] and [CA2637] do not appear after you set the KDPF Memory.
At this point, the procedure to prevent fuel dose injection is stopped, which was necessary
when this failure code was shown.
40-492 HD465-8, HD605-8


Action level Failure code Manual Stationary Regeneration Request
Failure
Manual Stationary Regeneration request prompts an operator to perform manual stationary regeneration,
Details of fail- which does more soot removal than automatic regeneration. This is done when a larger quantity of soot
ure accumulates in the KCSF of the KDPF than the quantity of soot that triggers automatic regeneration.
Soot accumulation reaches level 4 or 5.
Procedure of
Normal control
controller
NOTICE
q Perform manual stationary regeneration when failure code [CA2639] is shown.
q This failure code is shown during manual stationary regeneration, this is normal.
q If this failure code remains on the machine monitor for several hours after manual stationary re-
generation, troubleshoot as follows.
k KDOC and KDPF become hot (Minimum. 500 °C). Be careful not to become burned.
3. From the service menu of the machine monitor, display the Diagnostic Tests screen, open Active Regen-
Related infor-
eration for Service, and then perform manual stationary regeneration.
mation
q Switch operation during manual stationary regeneration: Push "1", "2", "3" in sequence while
numeral input switch [4] is pushed, the screen changes to the monitor screen.
Time required to complete manual stationary regeneration varies by the quantity of soot accumulated in the
KCSF as described below.
q Soot accumulation level 8: Manual stationary regenerations prevented.
q If other failure codes are shown, which include manual stationary regeneration), troubleshoot for it first.
q After the repair is completed, remove the failure code by these procedures.
No. Cause Procedures, test location, measure standards and notes.
Increased soot accumula- Make sure that the regeneration disable button is not pushed on the machine monitor.
1 tion because of stopped REMARK
regeneration If it is pushed, it stops the Regeneration Disable.
When the KDPF cools down sufficiently or there is a large difference between KDOC inlet
and KDPF outlet temperatures at idle (non-regeneration), replace the sensor.
REMARK
2 monitoring function. (Code: 47300)
perature sensor
q When failure code [AQ00N3] or [AQ00N4] is displayed at an altitude of 3000 m or
higher, the exhaust flow that is necessary for the stationary regeneration may be un-
Uneven soot accumulation able to be secured on one of two after treatment systems.
3 in a high altitude environ- q Ten minutes after stationary regeneration starts examine the values of these two mon-
ment itor codes. Make sure that 47500 Dosing Instant Fuel Consumption (per device) and
47501 Dosing Instant Fuel Consumption (per device)_2 are not 0 (l/hr.). If one of those
is continuously 0 (l/hr.), replace the two KDPFs.
HD465-8, HD605-8 40-493


q Check VGT for mechanical failure.
q Make sure that there is no unwanted material in the oil line of VGT servo.
q Perform the manual stationary regeneration. At this time, if KDOC inlet temperature
remains at approximately 250 °C or below and VGT solenoid current remains at ap-
4 Defective VGT proximately 1000 mA, VGT is defective. (Approximate time taken for manual station-
ary regeneration depends on accumulation of soot. See the failure code [CA2639].)
REMARK
VGT solenoid current can be checked by the monitoring function. (Code: 48800 (mA))
Defective KDPF (KDOC,
5 Perform troubleshooting for Active Regeneration Takes Time in S mode.
KCSF)
Defective exhaust gas q If excess black smoke is seen at high idle or when the engine accelerates, perform
6
color "KDPF GETS CLOGGED IN A SHORT TIME".
q If black smoke comes out when the engine accelerates, but disappears at high idle,
there is no problem.
If no failure is found with these procedures, the engine controller is defective. (Since this
40-494 HD465-8, HD605-8


Action level Failure code Fuel Doser Solenoid 2 High Error
Failure
Details of fail-
High-voltage Fault is sensed in circuit of fuel doser solenoid valve 2 (drain valve).
ure
Procedure of
controller
q Automatic regeneration is not performed.
Machine Event
q Manual stationary regeneration is disabled.
k Exhaust connector and KDPF become hot (Minimum. 500 °C). Be careful not to become burned.

connector

2. Disconnect connector AFT1_SOV2, and connect T-adapter to male side.
2
noid valve 2 Between AFT1_SOV2 (male) (2) and (1) 4 to 6 Ω
Resistance Minimum. 1
Between AFT1_SOV2 (male) (1) and ground
MΩ

2. Disconnect connectors ECM1 J1 and AFT1_SOV2, and connect T-adapter to each
female side.
3 Between ECM1 J1 (female) (6) and AFT1_SOV2 (female) Maximum. 1
ness
(1) Ω
Resistance
Between ECM1 J1 (female) (30) and AFT1_SOV2 (female) Maximum. 1
(2) Ω

2. Disconnect connector AFT1_SOV2, and connect T-adapter to female side.
4
harness
Maximum.
Voltage Between AFT1_SOV2 (female) (1) and (2)
4.7 V
1. Start and run the engine at low idle speed for approximately 1 minute.
2. If any other failure code is shown, troubleshoot for that code.
If a failure code is shown and no failure found with the checks, the engine controller is
defective. (Since this is an internal problem, you cannot troubleshoot.)
HD465-8, HD605-8 40-495

Circuit diagram related to the solenoid valve 2 of the fuel doser
40-496 HD465-8, HD605-8


Action level Failure code Fuel Doser Solenoid 2 Low Error
Failure
Details of fail-
Low voltage error is sensed in the valve 2 circuit of the fuel doser solenoid (drain valve).
ure
Procedure of
controller
Machine Event
Related infor- q This failure code is removed after the failure is eliminated. Solenoid valve 2 of the fuel doser operates
mation again when you cycle the start switch ON and then OFF.
No. Cause Procedures, measured location, measured standards and remarks.

connector

2
noid valve 2 Between AFT1_SOV2 (male) (2) and (1) 4 to 6 Ω
Resistance Minimum. 1
Between AFT1_SOV2 (male) (1) and ground
MΩ

2. Disconnect connectors ECM1 J1 and AFT1_SOV2, and connect T-adapter to either
3
ness
Between ground and ECM1 J1 (female) (6) or AFT1_SOV1 Minimum. 1
Resistance
(female) (1) MΩ

2. Disconnect connectors ECM1 J1 and AFT1_SOV2, and connect T-adapter to female
4
ness
pin (6)
HD465-8, HD605-8 40-497

40-498 HD465-8, HD605-8


Action level Failure code Fuel Dozer Solenoid Valve Swap Error
Failure
Details of fail- Fuel Doser solenoid valve 1 (SHUTOFF valve) and fuel doser solenoid valve 2 (drain valve) are connected
ure incorrectly.
Procedure of
controller
Machine Event
Related infor- How to clear the failure code
mation Turn the start switch from OFF to ON and start the engine. The failure code is removed after you operate
the engine at low idle for approximately 3 minutes, and then the repair is completed.

Reverse connection of wire
1 Check connectors AFT1_SOV1 and AFT1_SOV2.
harness connector

1A. Fuel doser-A
1B. Fuel doser-B
a: From fuel pump-A
b: From fuel pump-B
c: Fuel return
tor
HD465-8, HD605-8 40-499


Action level Failure code Injector Trim Data Mismatch
Failure
Details of fail- q The data of the injector trim entered into the engine controller is not correct.
ure q The same injector trim data was input in multiple injectors.
Procedure of
Does not perform injector compensation.
controller
Machine Event Engine power increases or decreases.
Related infor- After the repair is completed, remove the failure code by these procedures.
mation Turn the start switch to the ON position.
1. Since input value of injector trim data may be incorrect, check the input value.
Incorrect input of injector 2. When you replace an injector, program the injector trim data. For details, see TEST
1
trim data AND ADJUST, "PROGRAM INJECTOR TRIM CODE VALUE TO ENGINE
CONTROLLER".
1. When more than one injector with the same injector trim data are installed, replace
only the applicable injector.
Input the same injector trim (If the data of two injectors overlaps, replace either of two injectors.)
2
data 2. After you replace, make sure that the trim data of the injectors does not overlap, and
input the injector trim data again. (For details, see TEST AND ADJUST, "PROGRAM
INJECTOR TRIM CODE VALUE TO ENGINE CONTROLLER".)
40-500 HD465-8, HD605-8


Action level Failure code Manual Stationary Regeneration Request but KDPF Regeneration Disable
Failure
- CA2777 (Engine controller system)
q Manual stationary regeneration request prompts an operator to perform manual stationary regeneration,
which removes soot more efficient than automatic regeneration.
Details of fail- This request is made because a larger quantity of soot accumulates in the KCSF in side the KDPF.
ure That quantity of soot triggers automatic regeneration. However, because the operator pushed the Re-
generation Disable switch, the regeneration is disabled and the failure code appears.
q Soot accumulation reaches level 4 or 5.
Procedure of
None in particular
controller
k KDOC and KDPF become hot (Minimum. 500 °C). Be careful not to get burned.
REMARK
Regeneration does not start, because the fuel dosing stops when KDOC inlet temperature is below approx-
imately 280 °C even if the controller starts manual stationary regeneration.
q The KDOC inlet, KDOC outlet, and the KDPF outlet temperatures display on the Pre-defined Monitor
screens.
q During manual stationary regeneration, KDOC inlet temperature is approximately 250 to 400 °C. The
KDOC outlet temperature and KDPF outlet temperature are approximately 450 to 600 °C.
How to complete Manual Stationary Regeneration
3. From Service menu of the machine monitor, display Diagnostic Tests screen, open Active Regeneration
for Service, clear Regeneration Disable, and then perform manual stationary regeneration.
Related infor- KCSF as described below.
mation q Soot accumulation level 4: Approximately 40 minutes to 1 hour
q Soot accumulation level 8: Manual stationary regeneration is prevented.
REMARK
q If this failure code remains on the machine monitor for several hours after manual stationary regenera-
tion is completed, troubleshoot with these procedures.
q If another failure code is also shown (which includes manual stationary regeneration), troubleshoot for
it first.
q This failure code shown refers to information that identifies a faulty part, not a failure itself.
q If this failure code is frequently shown, request the operator to cancel KDPF Regeneration Disable. Per-
form manual stationary regeneration after you secure the safety and area around the machine. Make
sure that there are no personnel or flammable materials near the machine.
If the failure code is NOT cleared after the Regeneration Disable is stopped, the engine
controller is defective. (Since this is an internal problem, you cannot troubleshoot.)
HD465-8, HD605-8 40-501


Action level Failure code Fuel Doser Solenoid 2 Servo Error
Failure
q During the pressure test immediately after the engine start. Fuel doser solenoid 2--A (AFT1_SOV2,
drain) ON/OFF command does not match estimated fuel pressure sensed by pressure sensor of the fuel
doser.
Details of fail-
q When Open AFT1_SOV1 and Close AFT1_SOV2 commands are given, the fuel dosing pressure
ure
sensed by the pressure sensor of the fuel doser does not increase sufficiently.
q When Close AFT1_SOV1 Valve and Open AFT1_SOV2 Valve commands are given, the dosing fuel
pressure sensed by dosing fuel pressure sensor does not decrease sufficiently.
Procedure of
controller
Phenomenon q Automatic regeneration is not performed.
on machine q Manual stationary regeneration is disabled.
may be defective. Troubleshoot for [CA1923], [CA1924], or [CA1925] initially.
Related infor- q If the failure code [CA1927] or [CA1928] is shown, the fuel doser solenoid valve 2 system may be de-
mation fective. Troubleshoot for [CA1927] or [CA1928].
Turn the start switch from the OFF to the ON position and start the engine. When the failure code is
removed after you run the engine at low idle for approximately 3 minutes, the repair is completed.

connector

2. Disconnect connectors AFT1_SOV1 and AFT1_SOV2.
3. Replace fuel doser solenoid valve 1 with the fuel doser solenoid valve 2.
Defective fuel doser sole- REMARK
2
noid valve 2 Do not replace the connector AFT1_SOV1 with AFT1_SOV2.
If this failure code changes to the code [CA1963], the original fuel doser solenoid valve 2
is defective.
3 Blocked fuel return pipe Remove the fuel return pipe and check for blockage.
4 Defective Fuel system Perform TEST AND ADJUST, "FUEL PRESSURE TEST".
Defective air intake mani- Remove the fuel pipe and to examine for blockage in the fuel connector in the fuel SHUT-
5
fold OFF manifold.

Defective dosing fuel pres-
6 4. Display the dosing fuel pressure (monitoring code: 47600) and ambient pressure
sure sensor
(monitoring code: 37400) at the same time on the machine monitor.
If the dosing fuel pressure and ambient pressure are quite different, the dosing fuel pres-
sure sensor is defective.
40-502 HD465-8, HD605-8



1A. Fuel doser-A
1B. Fuel doser-B
a: From fuel pump-A
b: From fuel pump-B
c: Fuel return
tor
HD465-8, HD605-8 40-503


Action level Failure code Dosing Fuel Pressure Low Error 1
Failure
Details of fail-
Pressure sensed by dosing fuel pressure sensor during dosing is below the value (the fuel pressure is low).
ure
Procedure of
q Above procedure is stopped when you move the start switch from the OFF to the ON position after the
controller
failure code is shown.
Machine Event
q If the failure code [CA1923], [CA1924], or [CA1925] is shown, the fuel doser solenoid 1 system may be
defective. Troubleshoot for [CA1923], [CA1924], or [CA1925] initially.
q If the failure code [CA2732] or [CA2733] is shown, the fuel doser solenoid 2 system may be defective.
Troubleshoot for [CA2732] or [CA2733].
q If the failure code [CA1927] or [CA1928] is shown, the fuel doser solenoid 2 system may be defective.
Troubleshoot for [CA1927] or [CA1928].
Related infor- q If the failure code [CA559] is shown, the fuel supply pump may be defective. Troubleshoot for [CA559]
mation initially.
q If the failure code [CA2265] or [CA2266] is shown, the supply pump system may be defective. Trouble-
shoot for [CA2265] or [CA2266] initially.
NOTICE
After you investigate the problem, and complete the repair, perform the Loaded Diagnostics Oper-
ation To remove the failure code and make sure it is removed. (This failure code is not removed
when you only turn the start switch to the ON position.)

connector
2 Fuel filter blockage Inspect the fuel filter for blockage.
Blocked fuel filter or fuel leak-
4 Inspect the fuel supply pipe and the joint bolt (JB).
age at the connections.
Defective air intake mani- Remove the fuel pipe and to examine for blockage in the fuel connector in the fuel SHUT-
5
fold OFF manifold.

sure sensor
q Replace fuel doser solenoid valve 2-A (4A).
7 q If this failure code is not removed, the original fuel doser solenoid valve 2-A is defec-
noid valve 2-A
tive.
40-504 HD465-8, HD605-8


Make sure the repair is completed using these procedures:
1. Turn the start switch from the OFF position to ON position.
2. Start the engine and run it at low idle speed for 1 minute.
3. Perform "Active Regeneration for Service". For details, see TEST AND ADJUST, "SERVICE MODE" and "PROCEDURE
TO OPERATE REGENERATION FOR SERVICE TEST MENU" under "SET AND OPERATE OF MACHINE MONITOR".
NOTICE
If the failure code is removed after Active Regeneration for Service is complete, then repair is completed.

1A. Fuel doser-A
1B. Fuel doser-B
a: From fuel pump-A
b: From fuel pump-B
c: Fuel return
tor AFT1_SOV2: Fuel doser solenoid valve 2-A (drain valve) con-
nector
HD465-8, HD605-8 40-505

40-506 HD465-8, HD605-8


Action level Failure code KDPF Outlet Pressure Sensor High Error
Failure
Details of fail-
High voltage is generated in the signal circuit of KDPF outlet pressure sensor.
ure
q Drives with KDPF outlet pressure sensor value at 0 kPa.
Procedure of q Closes EGR valve.
controller q Derates the engine power for operation.
Machine Event Engine power decreases.
k KDPF becomes hot (Minimum. 500 °C). Be careful not to become burned.
q If the failure code [CA1695] or [CA1696] is shown, the sensor power supply may be defective. Perform
troubleshooting for [CA1695] or [CA1696] initially.
q Signal voltage from the KDPF outlet pressure sensor can be checked by the monitoring function. (Code:
mation q Differential pressure detected by the KDPF outlet pressure sensor can be checked by the monitoring

connector

Defective KDPF outlet
2
pressure sensor If this failure code changes to [CA3134], KDPF outlet pressure sensor is defective.
REMARK

2. Disconnect connectors ECM1 J2 and DPFP1, and connect T-adapter to each female
3
ness
Maximum. 1
Resistance Between ECM1 J2 (female) (32) and DPFP1 (female) (1)
Ω

Hot short circuit in wiring 3. Connect T-adapter to female side of the connector DPFP1, or insert T-adapter into
4 connector ECM1 J2.
harness
Between DPFP1 (female) (3) and (1), or between ECM1 J2
Voltage Max. 1 V
(42) and (32)

2. Disconnect connectors ECM1 J2 and DPFP1, and connect T-adapter to female side
5
ness
pin (42)
HD465-8, HD605-8 40-507


Circuit diagram related to KDPF outlet pressure sensor
40-508 HD465-8, HD605-8


Action level Failure code KDPF Outlet Pressure Sensor Low Error
Failure
Details of fail-
Low voltage is generated in the signal circuit of KDPF outlet pressure sensor.
ure
Procedure of q Closes EGR valve.

connector

2. Disconnect connectors ECM1 J2 and DPFP1, and connect T-adapter to each female
side.
Maximum. 1
Open circuit in wiring har- Between ECM1 J2 (female) (32) and DPFP1 (female) (1)
2 Ω
ness
Maximum. 1
Resistance Between ECM1 J2 (female) (8) and DPFP1 (female) (4)
Ω
Maximum. 1
Between ECM1 J2 (female) (42) and DPFP1 (female) (3)
Ω

2. Disconnect connectors ECM1 J2 and DPFP1, and connect T-adapter to either female
3
ness
Between ground and ECM1 J2 (female) (42) or DPFP1 Minimum. 1
Resistance
(female) (3) MΩ

4
ness
pin (42)
HD465-8, HD605-8 40-509


Defective KDPF outlet 2. Insert T-adapter into connector DPFP1.
pressure sensor
Voltage Between DPFP1 (3) and (1) 0.5 to 4.5 V
40-510 HD465-8, HD605-8


Action level Failure code KDPF Outlet Pressure Sensor In Range Error
Failure
Details of fail- Pressure sensed by the KDPF out pressure sensor indicates a value higher than normal condition. (Signal
ure voltage is in operation range.)
q Drives KDPF outlet pressure sensor value at 0 kPa (gauge pressure).
q Stops EGR valve operation.
Procedure of
controller
q To start the engine, turn the start switch OFF, wait for the operation light to go off, then turn the start
Related infor- switch ON.
mation
NOTICE
q After you investigate the problem and complete the repair, perform Loaded Diagnostics Opera-
tion To Confirm Failure Correction to make sure this failure code is removed.

connector
1. Remove KDPF differential pressure sensor pipe.

2. Clean the pipe of the KDPF differential pressure sensor pipe.
3. Examine KDPF differential pressure sensor pipe for cracks and damage.
4. Install the KDPF differential pressure sensor pipe with the two pipes connected
Defective KDPF differen- correctly.
2 5. Perform Loaded Diagnostics Operation To Make sure Failure is Corrected.
tial pressure sensor pipe.
REMARK
HD465-8, HD605-8 40-511


2. Disconnect connector PDPF.
If the failure code [CA3134] is not shown, the wiring harness or engine controller is defec-
tive.
REMARK

Defective wiring harness or 2. Disconnect connector DPFP1, and connect the short socket adapter to female side.
3 Connect 5 V to the signal line. (Short-circuit pins (4) and (3) of connector DPFP1.)
engine controller
REMARK
If the failure code [CA3133] is not shown, the wiring harness or engine controller is defec-
tive.
REMARK
Defective KDPF outlet If the failure codes [CA3134] and [CA3133] shown with the procedure above, the KDPF
4
pressure sensor out pressure sensor is defective.
Loaded Diagnostics Operation To Confirm Failure Correction

REMARK
If this failure code is shown during the Loaded Diagnostics Operation To Confirm Failure Correction, go back to the trouble-
shooting procedures.
2. Remove this failure code by Engine Controller in Engine Controller Active Fault Clear from the service mode of the machine
monitor.
3. Turn the start switch to the OFF position to stop the engine controller.
5. Run the engine at low idle for approximately 1 minute.
6. Stall the torque converter continuously for approximately 1 minute as described below with the accelerator pedal pushed
at 100% full position.
1) Make sure that the park brake switch is set to the "PARK" position. Be sure to set the gear shift lever to the "D" position
k Be sure to set the gear shift lever to the "D" position while the torque converter is stalled. This will avoid
internal damage to the transmission.
40-512 HD465-8, HD605-8

2) Slowly depress of the accelerator pedal with the brake pedal depressed to stall the torque converter.
NOTICE
Make sure that the torque converter oil does not become too hot.
REMARK
30100)
7. If the oil temperature rises, switch operation to low idle or high idle to lower it.
8. Repeat steps 6 and 7 continuously for approximately 50 minutes while you are careful that the torque converter oil does
not become too hot.
9. Make sure that this failure code is not shown.
REMARK
q If this failure code is not shown, repair is completed.
q If this failure code is shown, go back to the troubleshooting procedures.
HD465-8, HD605-8 40-513


Action level Failure code Fuel Doser Degradation
Failure
Details of fail- q Fuel doser is deteriorated.

ure q The injection port of fuel doser is blocked.
Procedure of
None in particular
controller
It takes time to perform automatic regeneration. (KDOC outlet temperature does not rise easily and it takes
Machine Event
much time to burn the soot.)
q If the failure code [CA1927] or [CA1928] is shown, the fuel doser pressure sensor system may be de-
fective. Troubleshoot for [CA1927] or [CA1928] initially.
may be defective. Troubleshoot for [CA1923], [CA1924], or [CA1925] initially.
q If the failure code [CA1977] is shown, the fuel doser system may be defective. Troubleshoot for
[CA1977] initially.
q If the failure code [CA1963], [CA2878], or [CA2881] is shown, the fuel doser solenoid valve system may
be defective. Troubleshoot for [CA1963], [CA2878], or [CA2881] initially.
q Since this failure code has no action level, it is not shown on the user screen of the machine monitor.
This is displayed on the Service Menu and KOMTRAX terminal of the machine monitor.
Related infor-
mation
NOTICE
q If this failure code is shown, the injection quantity of fuel doser is corrected. After the repair is
completed, make sure to perform Fuel Doser Memory Reset to set the information to the correct-
ed doser injection quantity.
If you do not set the fuel doser information, it may cause damage to the KCSF.
q To complete the repair for this failure code, perform "fuel doser information reset" after you in-
vestigate the cause of and repair the problem.
Also, when the fuel doser is replaced, to complete that repair, perform "fuel doser information
reset".
This failure code is not removed when you just complete the "fuel doser information reset". The
failure code is removed the next time automatic regeneration is completed.

connector

2. Remove the fuel doser (1A) from the exhaust connector.
The injection port of fuel 3. Clean the fuel doser
2
the doser is blocked.
REMARK
To clean the fuel doser, see RELATED INFORMATION ON TROUBLESHOOTING.
40-514 HD465-8, HD605-8


2. Remove the fuel doser-A (1A) from the exhaust connector.
3. Install the fuel doser A (1A) for replacement to the exhaust connector.
REMARK
Install the doser to prevent exhaust gas leak from fuel doser mount hole.
3 Defective Fuel doser 4. Turn the starting switch to the ON position.
5. Perform Regeneration Disable
7. Run it at low idle, and wait for 2 minutes.
If there is no oil leakage from the tip of the fuel doser-A (1A), the original fuel doser-A (1A)
is defective.
1. Perform Fuel Doser Memory Reset.

Defective Fuel doser sys- 2. If this failure code is shown again after you perform these procedures above, the doser
4
tem fuel block is obstructed with unwanted materials. Replace the doser fuel block. After
replacement, perform How to Reset Fuel Doser Information. (See below.)
How to Perform Fuel Doser Memory Reset.

2. From Service Menu of the machine monitor, open KDPF Memory Reset and perform KDPF Cleaning.
q If this failure code is shown, the injection quantity of fuel doser is corrected. After the repair is completed, make sure to
perform Fuel Doser Memory Reset to set the information to the corrected doser injection quantity.
q If you do not set the fuel doser information, will cause damage to KCSF.

1A. Fuel doser-A
1B. Fuel doser-B
a: From fuel pump-A
b: From fuel pump-B
c: Fuel return
nector AFT2_PFUEL: Fuel doser pressure sensor-B connector
HD465-8, HD605-8 40-515


Action level Failure code KDOC Inlet Temperature High Error
Failure
Details of fail-
KDOC inlet temperature remains high.
ure
Procedure of q Stops EGR valve operation.
controller q Derates the engine power.
k KDPF and KDOC become hot (Minimum. 500 °C). Be careful not to become burned.
q If the failure code [CA3313], [CA3314], or [CA3315] is shown, KDOC inlet the temperature sensor may
be defective. Troubleshoot for [CA3313], [CA3314], or [CA3315].
q If the failure code [CA1925] or [CA1963] is shown, the fuel doser solenoid valve 1 may be defective.
Troubleshoot for [CA1925] or [CA1963] initially.
q When a misfire of the cylinder occurs:
1. Combustion is decreased, which causes higher exhaust temperature.
2. Cylinders compensate for the torque drop due to a defective cylinder by an increase of fuel injection.
This may cause higher exhaust temperature.
q Engine derate is stopped when you turn the start switch to the OFF position after this failure code is
removed. (This derate is not stopped when you only remove the failure code.)
NOTICE
Related infor- If this failure code is shown, it may caused damage to the KCSF. Inspect these after you repair the
mation failure code. Replace the KCSF if the black smoke comes out of the exhaust pipe outlet (tale pipe
outlet).
q Start the engine, quickly accelerate the engine from low idle speed to high idle speed twice, and then
keep the engine at high idle speed for 5 seconds.
q Make sure that black smoke does not come out of the exhaust pipe outlet when you accelerate and at
high idle.
NOTICE
q After you investigate the problem, and complete the repair, perform the Loaded Diagnostics Op-
eration To remove the failure code and make sure it is removed. (This failure code is not removed

connector
Inspect air intake hoses, clamps, and pipes, make sure the clamps and pipes are tight
2 Defective air intake system
and not damaged. Make repairs as necessary.
As a result of the cylinder cut-out mode, a cylinder that operates with no changed in speed
3 Defective injector
is found. (See TEST AND ADJUST, "CYLINDER CUT-OUT MODE)".
1. Remove the turbocharger exhaust connector.

2. Inspect for oil or fuel stuck to the inner side of the turbocharger exhaust connector.
Oil leaks into the turbo- NOTICE
4
charger exhaust connector q If oil or fuel is stuck, visually examine the EGR valve and turbocharger for oil
leaks. Repair as necessary if a defect is found.
q Clean the oil or fuel that is stuck to the pipes.
40-516 HD465-8, HD605-8


Examine the exhaust system between the turbocharger and KDPF for entry of oil or fuel.
Oil leaks into the exhaust q If oil or fuel is stuck, clean it completely.
5
connector or pipe to KDPF q If there are signs that oil or fuel flowed into the KDPF, inspect the KDPF, and then
clean or replace as required.
Defective installation of For details, see DISASSEMBLY AND ASSEMBLY, "REMOVE AND INSTALL KDPF
6 KDOC inlet temperature ASSEMBLY" and "DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY". Repair as
sensor necessary.
Defective KDPF tempera- If the failure code is not removed with the above procedures, replace the KDPF tempera-
7
ture sensor ture sensor.

2. Run the engine at low idle for approximately 15 minutes.
NOTICE
If this failure code is cleared, the repair is completed.
HD465-8, HD605-8 40-517


Action level Failure code KDOC Temperature Error - Non Regeneration
Failure
Details of fail-
KDOC outlet temperature remains at high level when Active Regeneration is not performed.
ure
Procedure of q Derates the engine power for operation.
controller q Stops the fuel dosing.
q If the failure code [CA3313], [CA3314], or [CA3315] is shown, KDOC inlet the temperature sensor may
1. Combustion is decreased, which will cause higher exhaust temperature.
NOTICE
Related infor-
mation If this failure code is shown, it may caused damage to the KCSF. Inspect these after you repair the
failure code. Replace the KCSF if the black smoke comes out of the exhaust pipe outlet (tale pipe
outlet).
high idle.
NOTICE

connector
40-518 HD465-8, HD605-8


4
charger exhaust connector q If oil or fuel are found, examine the EGR valve and turbocharger for oil leaks.
Repair as necessary if a defect is found.
5
1. Remove KDPF.
2. Remove KDOC.
KDOC.
Defective KDOC
damage)
REMARK
KDOC function)
REMARK
sensor necessary.
9 KDOC outlet temperature ASSEMBLY" and "DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY". Repair as
sensor necessary.
10
HD465-8, HD605-8 40-519



(Make sure that the failure codes is removed after this procedure.)
k Put the machine on a level ground, set the parking brake switch to "PARK" position, and chock the tires.
2. Run the engine at low idle for approximately 15 minutes, if the failure code clears, the repair is completed. If the failure code
does not clear, perform these procedures.
NOTICE
If the failure code is not cleared after steps 1 and 2 are performed, make sure the temperature requirement neces-
sary for the clearing are satisfied. Steps 5 and 6 are the operation to satisfy the temperature requirements.
q KDOC inlet temperature is 200 °C or higher.
q KDOC outlet temperature is 200 °C or higher.
3. Display the KDOC inlet outlet temperature with the monitor function.
REMARK
NOTICE
The engine speed will not increase to high idle approximately 2270 rpm, without the release of the park brake.
5. Run the engine at high idle speed (approximately 2270 rpm) with depressing the brake pedal continuously for 15 minutes.
6. If the KDOC inlet or outlet temperature does not exceed 200 °C or higher, perform Loaded Diagnostics Operation To Clear
Failure Code for failure code [CA1883].
7. Make sure that this failure code is removed.
REMARK
q If this failure code is cleared, the repair is completed.
q If this failure code is not removed, go back to the troubleshooting.
40-520 HD465-8, HD605-8


Action level Failure code KDOC Outlet Temperature High Error 1
Failure
Details of fail-
KDOC outlet temperature remains at high level.
ure
Procedure of
None in particular
controller
1.Combustion is decreased, which will cause higher exhaust temperatures.
2.Cylinders compensate for the torque drop due to a defective cylinder by an increase of fuel injection.
NOTICE
If this failure code is shown, it may caused damage to the KCSF. Inspect these after you repair the
Related infor-
mation outlet).
q Quickly accelerate the engine from low to high idle twice, and then keep the engine at high idle speed
for 5 seconds.
high idle.
NOTICE


3
4
HD465-8, HD605-8 40-521

1. Remove KDPF.
2. Remove KDOC.
KDOC.
Defective KDOC
damage)
REMARK
KDOC function)
REMARK
sensor necessary.
8

(Make sure that this failure code is cleared after this procedure.)
1. Turn the start switch from the OFF to the ON position.
2. Start the engine and run it at low idle speed for about 1 minute.
3. Perform Active Regeneration for Service.
4. End Active Regeneration for Service.
NOTICE
q Perform Active Regeneration for Servicer for 15 minutes or more.
q If the failure code is removed after Active Regeneration for Service is complete, then repair is completed.
40-522 HD465-8, HD605-8


Action level Failure code KDPF Temperature Error - Non Regeneration
Failure
Details of fail-
KDPF outlet temperature remains at high level when Active Regeneration is not performed.
ure
controller q Stops regeneration control.
q If the failure code [CA3319], [CA3321], or [CA3322] is shown, KDPF outlet temperature sensor may be
NOTICE
outlet).
Related infor-
q Quickly accelerate the engine from low to high idle twice, and then keep the engine at high idle speed
mation
for 5 seconds.
high idle.
NOTICE


3
4
sensor necessary.
6
HD465-8, HD605-8 40-523



2. Run the engine at low idle for approximately 15 minutes, if the failure code clears, the repair is completed. If the failure code
does not clear, perform these procedures.
NOTICE
If the failure code is not cleared after steps 1 and 2 are performed, make sure the temperature requirement neces-
sary for the clearing are satisfied. Steps 5 and 6 are the operation to satisfy the temperature requirements.
q KDPF outlet temperature is 200 °C or higher.
3. Display KDOC outlet temperature and KDPF outlet temperature with the monitor function.
REMARK
q Temperature detected by KDPF outlet temperature sensor can be checked by the monitoring function. (Code: 47400)
NOTICE
6. If the KDOC outlet temperature or KDPF outlet temperature does not exceed 200 °C or higher, perform the Loaded Diag-
nostics Operation To Clear Failure Code for failure code [CA1883].
REMARK
q If this failure code is not cleared, go back to the troubleshooting procedures.
40-524 HD465-8, HD605-8


Action level Failure code KDPF Outlet Temperature High Error 1
Failure
Details of fail-
KDPF outlet temperature remains at high level.
ure
Procedure of
None in particular
controller
q If the failure codes [CA3319], [CA3321], or [CA3322] is shown, KDPF outlet temperature sensor may
1. Combustion is decreased, which will cause higher exhaust temperature.
q To start the engine, wait until the system operation lights is off after you turn the start switch to the OFF
position. Then turn the start switch to the ON position.
NOTICE
Related infor-
mation failure code. Replace the KCSF if the black smoke comes out of the exhaust pipe outlet (tale pipe
outlet).
high idle.
NOTICE
eration To remove the failure code and make sure it is removed.


3
4
sensor necessary.
6
HD465-8, HD605-8 40-525



4. From Service menu of the machine monitor, display Diagnostic Tests screen, open Active Regeneration for Service, and
then perform Manual Stationary Regeneration.
NOTICE
q Perform Active Regeneration for Servicer for a minimum 15 minutes.
q If the failure code is removed after Active Regeneration for Service is complete, then repair is completed.
40-526 HD465-8, HD605-8


Action level Failure code KDOC Outlet Temperature High Error 2
Failure
Details of fail-
KDOC outlet temperature remains at a high level compared to the KDOC inlet temperature.
ure
NOTICE
Related infor- outlet).
mation q Start the engine, quickly accelerate the engine from low idle speed to high idle speed twice, and then
high idle.
NOTICE
tion To Confirm Failure Correction to make sure this failure code is removed. (When this failure
code is not shown with the start switch turned ON, high exhaust temperature are required to
make sure the repair is completed.)


3
4
sensor necessary.
HD465-8, HD605-8 40-527


6

NOTICE
The failure code is removed once when the start switch is turned from the OFF to ON position. Make sure that the
failure code does not show again when the engine runs at low idle speed.
2. Start the engine and run it at low idle for 2 minutes.
NOTICE
When this failure code shows when the start switch is turned ON, engine not started, troubleshoot and repair this fail-
ure code initially. Then troubleshoot the other failure codes.
q [CA3316] KDOC Outlet Temperature Sensor Low Error
q [CA3317] KDOC Outlet Temperature Sensor High Error
40-528 HD465-8, HD605-8


Action level Failure code KDPF Outlet Temperature High Error 2
Failure
Details of fail-
ure
Procedure of
None in particular
controller
Phenomenon
None in particular
on machine
q If the failure code [CA3319], [CA3321], or [CA3322] is shown, KDPF outlet temperature sensor may be
1. Combustion is impaired, causing higher exhaust temperature.
NOTICE
Related infor- If this failure code is shown, it may caused damage to the KCSF. Inspect these after you repair the
mation
outlet).
high idle.
NOTICE


3
q Clean the oil or fuel stuck to the piping completely.
4
HD465-8, HD605-8 40-529


sensor necessary.
6

NOTICE
The failure code is removed once when the start switch is turned from the OFF to ON position. Make sure that the
failure code does not show again when the engine runs at low idle speed.
2. Start the engine and run it at low idle for 2 minutes.
NOTICE
When this failure code shows when the start switch is turned ON, engine not started, troubleshoot and repair this fail-
ure code initially. Then troubleshoot the other failure codes.
q [CA3319] KDPF Outlet Temperature Sensor Low Error
q [CA3321] KDPF Outlet Temperature Sensor High Error
40-530 HD465-8, HD605-8


Action level Failure code KDOC Inlet Temperature Sensor Low Error
Failure
Details of fail- Ground fault or incorrect sensor circuit in the measured section or probe (+) side of the KDOC inlet temper-
ure ature sensor
q Replaces the KDOC outlet temperature for KDOC inlet temperature to run the engine. (If the KDOC out-
let temperature sensor is also defective, uses a set value of 250 °C and runs the engine.)
controller q Stops EGR valve operation.
q Defective active regeneration control
Machine Event q Soot accumulation is high.
q Engine power decreases.
Related infor- q Engine derate is stopped when you turn the start switch to the OFF position after this failure code is
mation removed. (This derate is not stopped when you only remove the failure code.)
connector
Defective KDOC inlet tem-

REMARK
2 To access KDOC inlet temperature sensor, KDOC outlet temperature sensor, and KDPF
perature sensor
outlet temperature sensor, see DISASSEMBLY AND ASSEMBLY, "REMOVE AND
INSTALL KDPF ASSEMBLY" and "DISASSEMBLE AND ASSEMBLE OF KDPF ASSEM-
BLY".
HD465-8, HD605-8 40-531


Action level Failure code KDOC Inlet Temperature Sensor High Error
Failure
Details of fail- Open circuit, hot short circuit, or incorrect sensor circuit in the measured section or probe (+) side of the
ure KDOC inlet temperature sensor
q Replaces the KDOC outlet temperature for KDOC inlet temperature to run the engine. (If the KDOC out-
let temperature sensor is also defective, uses a set value of 250 °C and runs the engine.)

connector

REMARK
perature sensor
BLY".
40-532 HD465-8, HD605-8


Action level Failure code KDOC Inlet Temperature Sensor In Range Error
Failure
Details of fail- The temperature difference between the KDOC inlet and KDOC outlet temperature sensors differs from the
ure expected value. (Signal voltage is in input range.)
q Substitute the KDOC outlet temperature for KDOC inlet temperature to run the engine. (If the KDOC
outlet temperature sensor is also defective, use KDOC inlet temperature as a default value at 250 °C
and run the engine.)
Procedure of
controller
q If the failure code [CA3313] and [CA3314] are displayed, KDOC inlet temperature sensor may be de-
fective. Perform troubleshooting for [CA3313] and [CA3314].
Related infor- q To restart the engine, wait until the system operating lamp goes out after turning the starting switch to
mation OFF position, and then turn the starting switch to ON position.
NOTICE

connector
REMARK
Defective KDOC inlet tem- q Temperature detected by KDOC outlet temperature sensor can be checked by the
perature sensor
To access KDOC inlet temperature sensor, KDOC outlet temperature sensor, and KDPF
BLY".
HD465-8, HD605-8 40-533


5
Oil leakage into turbo- NOTICE
Oil leakage into exhaust q If oil or fuel is stuck, clean it completely.
6
connector or duct to KDPF q If there are signs that oil or fuel flowed into the KDPF, inspect the KDPF, and then
sensor necessary.
8

REMARK

monitor.
NOTICE
REMARK
30100)
not become too hot.
40-534 HD465-8, HD605-8

REMARK
HD465-8, HD605-8 40-535


Action level Failure code KDOC Outlet Temperature Sensor Low Error
Failure
Details of fail- Ground fault or incorrect sensor circuit in the measured section or probe (+) side of the outlet temperature
ure sensor of the KDOC
q Replaces the KDOC inlet temperature for KDOC outlet temperature to run the engine, because the
KDOC outlet temperature is not sensed. (If the KDOC inlet temperature sensor is also defective, the
controller uses the set value (250 °C) to run the engine.)
Procedure of
controller

connector
1. Examine the sensor connector for any tension or damage

3. Replace KDPF temperature sensor.
REMARK
Defective KDOC outlet
temperature sensor
BLY".
If this failure code is not displayed, the original KDPF outlet temperature sensor is defec-
tive. (Since this is an internal defect, troubleshooting cannot be performed.)
40-536 HD465-8, HD605-8


Action level Failure code KDOC Outlet Temperature Sensor High Error
Failure
Details of fail- Open circuit, hot short circuit, or incorrect sensor circuit in the measured section or probe of the (+) side of
ure the KDOC outlet temperature sensor
q Replaces the KDOC inlet temperature for KDOC outlet temperature to run the engine, because the
Procedure of
controller

connector

REMARK
temperature sensor
BLY".
HD465-8, HD605-8 40-537


Action level Failure code KDOC Outlet Temperature Sensor In Range Error
Failure
The difference between the temperature sensed by the KDOC outlet temperature sensor and the tempera-
Details of fail-
ture sensed by the KDOC inlet temperature sensor differs from the expected value. (Signal voltage is in
ure
input range.)
q Substitutes the KDOC inlet temperature for KDOC outlet temperature to run the engine, because KDOC
outlet temperature is not sensed. (If the KDOC inlet temperature sensor is also defective, the controller
uses the set value (250 °C) to run the engine.)
Procedure of
controller
q If the failure code [CA3316] and [CA3317] are shown, KDOC outlet temperature sensor may be defec-
tive. Troubleshoot for [CA3316] and [CA3317].
(Code: 47300)
(Code: 47400)
q To start the engine, turn the start switch OFF, wait for the operation light to go off, then turn the start
switch ON.
NOTICE

connector

REMARK
temperature sensor
BLY".
40-538 HD465-8, HD605-8



5
6
sensor necessary.
1. Perform Loaded Diagnostics Operation To Make sure Failure is Corrected.

Defective KDPF tempera- 2. If the failure code is not removed with the above procedures, replace the KDPF
8
ture sensor temperature sensor.

REMARK
monitor.
NOTICE
REMARK
30100)
HD465-8, HD605-8 40-539

not become too hot.
REMARK
40-540 HD465-8, HD605-8


Action level Failure code KDPF Outlet Temperature Sensor High Error
Failure
Details of fail- Open circuit, hot short circuit, or incorrect sensor circuit in the measured section or probe (+) side of the
ure KDPF outlet temperature sensor
q Replaces the KDOC outlet temperature for KDPF outlet temperature to run the engine. (If the KDOC
outlet temperature sensor is also defective, the controller uses KDPF outlet temperature as a set value
(250 °C) and runs the engine.)
Procedure of
controller
Machine Event
q Soot accumulation is high.

connector

REMARK
Defective KDPF outlet tem-
perature sensor
BLY".
HD465-8, HD605-8 40-541


Action level Failure code KDPF Outlet Temperature Sensor Low Error
Failure
Details of fail-
Ground fault in KDPF outlet temperature sensor measuring section or probe (+) side
ure
Procedure of
controller
Machine Event

connector

REMARK
perature sensor
BLY".
40-542 HD465-8, HD605-8


Action level Failure code KDPF Outlet Temperature Sensor In Range Error
Failure
Details of fail- The temperature sensed by KDPF outlet temperature sensor differs from the expected value. (Signal volt-
ure age is in input range.)
Procedure of
controller
q If the failure code [CA3319] and [CA3321] are shown, KDPF outlet temperature sensor may be defec-
tive. Troubleshoot for [CA3319] and [CA3321].
q Temperature detected by KDPF outlet temperature sensor can be checked by monitoring function.
(Code: 47200)
NOTICE

connector

REMARK
perature sensor
BLY".
HD465-8, HD605-8 40-543


5
6
sensor necessary.

Defective KDPF tempera- 2. If the failure code is not removed with the above procedures, replace the KDPF
8
ture sensor temperature sensor.

REMARK
monitor.
k Be sure to set the gear shift lever to the "D" position while the torque converter is stalled. This will avoid
internal damage to the transmission.
NOTICE
REMARK
30100)
40-544 HD465-8, HD605-8

not become too hot.
REMARK
HD465-8, HD605-8 40-545


Action level Failure code MAF Sensor Supply Voltage High Error
Failure
Details of fail-
High voltage is generated in mass air flow sensor power supply (12 V) circuit.
ure
Procedure of
None in particular
controller
q If failure code [CA356] or [CA357] is shown, perform the correction described in Action of the controller
of the related failure code.

Defective mass air flow
1 If this failure code is not shown, mass airflow and temperature sensor are defective.
REMARK
Many other failure codes appear at the same time. Ignore other failure codes caused by
the disconnected connectors.

2 If this failure code is not shown, wiring harness is defective.
harness
REMARK

Approxi-
Voltage Between ECM1 J1 (male) (80) and (56)
mately. 12 V
40-546 HD465-8, HD605-8

Mass airflow sensor circuit diagram
HD465-8, HD605-8 40-547


Action level Failure code MAF Sensor Supply Voltage Low Error
Failure
Details of fail-
Low voltage is generated in the mass airflow sensor power supply (12 V) circuit.
ure
Procedure of
None in particular
controller
q If failure code [CA356] or [CA357] is shown, perform the correction described in Action of the controller
of the related failure code.

connector

Defective mass air flow
2 If this failure code is not shown, mass airflow and temperature sensors are defective.
REMARK

3 If this failure code is not shown, wiring harness is defective.
harness
REMARK

2. Disconnect connector ECM1 J1, and connect T-adapter to the male side.
Voltage Between ECM1 J1 (male) (80) and (56) Approx. 12 V
40-548 HD465-8, HD605-8

Circuit diagram related to mass air flow sensor
HD465-8, HD605-8 40-549


Action level Failure code KDOC and KDPF Temperature Sensor Datalink Timeout Error
Failure
q Engine controller does not receive the data from the KDOC inlet or outlet, and the outlet temperature
Details of fail- sensor of the KDPF. This because of a communication error with the KDPF temperature sensor.
ure q This occurs when the information from the KDOC inlet and outlet, and temperature sensors for KDPF
outlet, are not received for a quantity of time.
q Uses KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature to run the en-
gine as a default value (250 °C).
q KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature detection is disabled.
k Exhaust connector for turbocharger, pipes for installed sensors, KDPF, and KDOC become hot
(Minimum 500 °C). Be careful not to become burned.

connector

2. Examine the circuit breaker FuB2 is opened.
2 Defective circuit breaker q If the circuit breaker is opened, troubleshoot for a ground fault in the wiring harness.
q If wiring harness has no ground fault, and if circuit breaker does not reset normally,
circuit breaker is defective.

2. Remove fuse No. 1 in fuse box BT5, and visually check if it is blown out.
3 Defective fuse 3. If the fuse is not blown, perform a continuity test to make sure it is not broken.
q If the fuse is blown, troubleshoot for a ground fault in the wiring harness.
q If the fuse is not blown but has no continuity, replace the fuse.

2. Disconnect connector DPFT1, and connect T adapter to each female side.
Open circuit in wiring har- Maximum 1
4 Between DPFT1 (female) (4) and battery relay terminal 77
ness (power supply circuit) Ω
Resistance
Maximum 1
Between DPFT1 (female) (1) and ground
Ω
40-550 HD465-8, HD605-8


2. Disconnect connectors DLK1 and CEN21_RES, and connect T adapter to each male
side.
Defective CAN terminating
5 Approxi-
resistor Between DLK1 (male) (A) and (B)
mately 120 Ω
Resistance
Approxi-
Between CEN21_RES (male) (A) and (B)
mately 120 Ω

2. Disconnect connectors ECM1 J2, DPFT1, DLK1, and CEN21_RES, and connect
T-adapter to each female side.
Maximum 1
Between ECM1 J2 (female) (21) and DPFT1 (female) (3)
Ω
Maximum 1
Between ECM1 J2 (female) (45) and DPFT1 (female) (2)
Ω
6 ness (CAN communication Maximum 1
line) Between DLK1 (female) (A) and DPFT1 (female) (3)
Ω
Resistance
Maximum 1
Between DLK1 (female) (B) and DPFT1 (female) (2)
Ω
Between CEN21_RES (female) (A) and DPFT1 (female)
Max. 1 Ω
(3)
Between CEN21_RES (female) (B) and DPFT1 (female)
Max. 1 Ω
(2)

2. Disconnect connectors ECM1 J2, DPFT1, DLK1, and CEN21_RES, and connect
T-adapter to female side to be measured.
Open circuit in wiring har- Between ground and either ECM1 J2 (female) (21), DLK1
7 ness (CAN communication Minimum 1
(female) (A), CEN21_RES (female) (A), or DPFT1 (female)
line) MΩ
(3)
Resistance
Between ground and either ECM1 J2 (female) (45), DLK1
Minimum 1
(female) (B), CEN21_RES (female) (B), or DPFT1 (female)
MΩ
(2)

2. Disconnect the connector CEN21_RES, and insert T-adapter.
8 harness (CAN communica-
tion line) Between CEN21_RES (A) and ground 1 to 4 V
Voltage
Between CEN21_RES (B) and ground 1 to 4 V

2. Replace KDPF temperature sensor (DPFT1).
Defective KDPF tempera- REMARK
9
ture sensor To replace the KDPF temperature sensor, see DISASSEMBLY AND ASSEMBLY, "DIS-
ASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY".
If this failure code is not shown, the initial sensor is defective. (Since this is an internal
problem, you cannot troubleshoot.)
HD465-8, HD605-8 40-551

Circuit diagram related to CAN system
40-552 HD465-8, HD605-8


Action level Failure code KDOC and KDPF Temperature Sensor Internal Circuit Error
Failure
Details of fail- Error is sensed in one of the sensor circuits, the KDOC inlet, KDOC outlet, or the KDPF outlet temperature
ure sensors.
q Uses KDOC inlet, KDOC outlet, and the KDPF outlet temperatures to run the engine at a set value (250
°C).
q The KDOC inlet, KDOC outlet, or the KDPF outlet temperature are not sensed.

connector

2. Replace the KDPF temperature sensor (DPFT1).
2
HD465-8, HD605-8 40-553

Circuit diagram related to the CAN system
40-554 HD465-8, HD605-8


Action level Failure code KDOC and KDPF Temperature Sensor ECU Voltage High Error
Failure
Details of fail-
High-voltage error is sensed in the power supply of the KDPF temperature sensor controller.
ure
gine as a fixed value (250 °C).
q The KDOC inlet, KDOC outlet, and KDPF outlet temperatures are not be sensed.

connector
Measure the battery voltage and specific gravity of the battery electrolyte.
Minimum 12
Battery voltage (for each battery)
V
2 Defective battery Minimum 24
Battery voltage (2 batteries in-line)
V
Minimum
Specific gravity of battery electrolyte
1.26

Defective input voltage of 2. Disconnect connector DPFT1, and connect T adapter to the female side.
KDPF temperature sensor
Voltage Between DPFT1 (female) (4) and (1) 20 to 30 V

4
HD465-8, HD605-8 40-555

Circuit diagram related to KDOC and KDPF temperature sensor
40-556 HD465-8, HD605-8


Action level Failure code KDOC and KDPF Temperature Sensor ECU Voltage Low Error
Failure
Details of fail-
Low voltage error is detected in power supply of KDPF temperature sensor controller.
ure
gine as a fixed value (250 °C).
q All of the KDOC inlet and outlet, and the KDPF outlet temperatures are not sensed.
Related infor-
mation Engine derate is stopped when you turn the start switch to the OFF position after this failure code is

connector
Minimum 12
V
V
Minimum
1.26

Defective input voltage of 2. Disconnect connector DPFT1, and connect T adapter to the female side.

4
HD465-8, HD605-8 40-557

40-558 HD465-8, HD605-8


Action level Failure code KDOC and KDPF Temperature Sensor ECU Over Temperature Error
Failure
Details of fail-
KDOC and KDPF Temperature Sensor ECU Over Temperature Error
ure
Procedure of
None in particular
controller
Machine Event
q All of the KDOC inlet and outlet, and the KDPF outlet temperatures are not sensed.
To start the engine, wait until the system operation lights is off after you turn the start switch to the OFF
mation After you investigate the problem and complete the repair, perform Loaded Diagnostics Operation
To Confirm Failure Correction to make sure this failure code is removed. (When this failure code is
not shown with the start switch turned ON, high exhaust temperature are required to make sure the
repair is completed.)

Make sure the temperature around the sensor controller is not abnormally high (150 °C or
1 Exhaust gas leakage
higher).

2

REMARK
1. Turn the start switch to the OFF position, and stop the engine.
2. Turn the start switch to ON position, and make sure the failure code is removed. If this failure code is shown, go back to
troubleshooting.
4. Run the engine at low idle speed for approximately 10 minutes.
5. Run the engine at high idle speed for 10 minutes.
6. If this failure code is removed, the repair is completed.
HD465-8, HD605-8 40-559

40-560 HD465-8, HD605-8


Action level Failure code KDOC and KDPF Temperature Sensor Power Interrupt Error
Failure
Details of fail- KDPF temperature sensor interrupt power failure error (12 open circuits are detected in the power supply
ure line in 60 seconds.)
q The factory value for the KDOC inlet and outlet, and the KDPF outlet temperatures (250 °C)
Procedure of
controller
q KDOC inlet and outlet, and the KDPF outlet temperatures error detected.
Machine Event q Defective regeneration control.
q Inspect the harness cover for damage or failure at the connector. Momentarily power loss is usually be-
cause of a loose or bad connection.
q To detect a broken wire, wiggle the wiring harness as much as possible while you measure the resis-
Related infor- tance to see if the value changes.
mation q Note that the sensor power supply relay connector is energized when the start switch is in the OFF po-
sition.
Procedure: Start the engine and operate the machine. (Apply vibration to the machine.)

connector

2. Disconnect connector DPFT1, and connect T-adapter to each female side
2
ness Between DPFT1 (female) (4) and battery relay terminal 77 Max. 1 Ω
Resistance
Between DPFT1 (female) (1) and ground Max. 1 Ω

3
HD465-8, HD605-8 40-561

40-562 HD465-8, HD605-8


Action level Failure code System Operating Lamp Short Circuit (Engine Controller)
Failure
Details of fail- Engine controller senses a short circuit. This occurs when the voltage output circuit does not go to a Low
ure level while the engine controller outputs current to the system operating lamp.
Procedure of
Stops driving system operating lamp.
controller

connector

2. While this failure code is shown, the system in operation lamp function is off. Turn the
battery disconnect switch OFF for 3 minutes or longer, after you turn the start switch
Hot short circuit in wiring to the OFF position.
2
harness 3. Disconnect connector OPL, and connect T-adapter to female side.
Voltage Between OPL (female) (2) and ground Max. 1 V

2. While this failure code is shown, the system in operation lamp function is off. Turn the
battery disconnect switch OFF for 3 minutes or longer, after you turn the start switch
to the OFF position.
3. Remove the fuse No.14 in fuse box BT4.
Short circuit in wiring har- 4. Disconnect connectors ATC3, KOM1A, MCM1, ECM1 J2, ECM2 J2, BRC3, OPC3,
3
ness KPS2, OPL, and CAB2 and connect T-adapter to female side of OPL.
REMARK
Connector OPC3 is only for the machine with ABS system.
Minimum 1
Resistance Between OPL (female) (1) and (2)
MΩ
HD465-8, HD605-8 40-563

Circuit diagram related to system operating lamp
40-564 HD465-8, HD605-8

Circuit diagram related to system operating lamp (Machine with ABS system)
HD465-8, HD605-8 40-565


Action level Failure code Ash Accumulation High Error
Failure
Details of fail-
There is much ash accumulation in KDPF. It is necessary to clean the ash.
ure
Procedure of
None in particular
controller
Machine Event KCSF may be damaged.
k KDPF becomes hot (Minimum 500 °C). Be careful not to become burned.
q If the failure code [CA1879], [CA1881], or [CA1883] is shown, the KDPF differential pressure sensor
may be defective. Troubleshoot for [CA1879], [CA1881], or [CA1883].
q If active regeneration is executed frequently, troubleshoot for "ACTIVE REGENERATION IS EXECUT-
ED FREQUENTLY" in S mode.
q When the ash accumulation goes to the upper limit, this failure code is shown.
Related infor- q This failure code is not displayed on the machine monitor, but is displayed on Abnormality Record
mation screen in service mode on the machine monitor and KOMTRAX terminal.
NOTICE
q When this failure code is shown, troubleshoot for defective differential pressure sensor of the
KDPF and defective KDPF (KDOC, KCSF), then make sure to clean out the ash.
q After you clean the ash, set the KDPF Clean and KDPF Change settings.
q If you do not set the fuel doser information, damage to the KCSF may occur.
NOTICE
Be sure to follow these procedures.
1. Remove KDPF, and clean out the ash accumulated in KDPF.
If the accumulated ash goes to the upper limit, it will cause high pressure loss of the
KDPF. Clean the KDPF.
Excessive ash accumula-
1 3. Perform the KDPF Clean or KDPF replace setting.
tion
To reset KDPF cleaning and KDPF replacing, see TEST AND ADJUST, "SERVICE
MODE" and "PROCEDURE TO OPERATE THE TEST MENU (KDPF MEMORY
RESET)" under "SET AND OPERATE OF MACHINE MONITOR".
4. Make sure that the ash accumulation level is 0 on the monitor screen.
Measure the ash accumulation level. For details, see TEST AND ADJUST, "service
MODE" and "PROCEDURE FOR OPERATE TEST MENU (ASH IN SOOT ACCUMU-
LATION CORRECTION)" under "SET AND OPERATE OF MACHINE MONITOR".
40-566 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [CB115]
FAILURE CODE [CB115]

Action level Failure code Engine NE and Backup Speed Sensor Error_2
Failure
L04 CB115 (Engine controller system)
Details of fail-
Errors occur at the same time in signal circuits of the NE speed sensor and Bkup speed sensor.
ure
Procedure of
Stops the engine.
controller
q Stopped engine cannot be started.
Machine Event
q Engine stops while it is in operation.
q When a error occurs in the Bkup speed sensor power supply. Failure code [CB352] Sensor Supply 1
Voltage Low Error_2 or [CB386] Sensor Supply 1 Voltage High Error_2 is shown. Troubleshoot for
[CB386] initially.
Related infor- q When an error occurs in the power supply for the E speed sensor supply. Failure code [CA238] NE
mation Speed Sensor Supply Voltage Error or Failure code [CA239] NE Speed Sensor Supply Voltage High
Error is shown. Troubleshoot for [CA239} initially.

connector
Inspect the NE speed sensor of the engine for possible damage or incorrect installation.
(loose).
installation
3 Inspect the flywheel for incorrect installation (loose).
wheel

2. Disconnect connectors ECM1 J1, ECM2 J1, and NE, and connect T-adapter to each
female side.
Maximum 1
Open circuit in wiring har- Between ECM1 J1 (female) (79) and NE (female) (1)
4 Ω
ness
Maximum 1
Resistance Between ECM1 J1 (female) (55) and NE (female) (2)
Ω
Maximum 1
Between ECM2 J1 (female) (31) and NE (female) (3)
Ω

Ground fault in wiring har- 2. Disconnect connectors ECM2 J1 and NE, and connect T-adapter to either female side.
5
ness Between ground and ECM2 J1 (female) (31) or NE Minimum 1
Resistance
(female) (3) MΩ

2. Disconnect connector NE, and connect T-adapter to female side.
6
harness
Maximum 1
Voltage Between NE (female) (3) and ground
V
HD465-8, HD605-8 40-567

FAILURE CODE [CB115] 40 TROUBLESHOOTING

2. Disconnect connectors ECM1 J1 and NE, and connect T-adapter to either female side.
Short circuit in wiring har- Between ECM1 J1 (female) (79) and (31), or between NE Minimum 1
7
ness (female) (1) and (3) MΩ
Resistance
Between ECM1 J1 (female) (55) and (31), or between NE Minimum 1
(female) (2) and (3) MΩ
REMARK
8 q
Bkup speed sensor or Inspect the engine Bkup sensor for possible damage or installation failure (installed incor-
9
defective installation rectly).
(mounted loosely)

10 Defective resistance 2. Disconnect connector P2_G_RES, and connect T-adapter to male side.

each female side.
Maximum 1
Open circuit in wiring har- Between ECM2 J1 (female) (78) and P2_G (female) (A)
11 Ω
ness
Maximum 1
Resistance Between ECM2 J1 (female) (54) and P2_G (female) (B)
Ω
Maximum 1
Between ECM2 J1 (female) (18) and P2_G (female) (C)
Ω

12
ness
Between ground and ECM2 J1 (female) (18) or P2_G Minimum 1
Resistance
(female) (C) MΩ

harness
Maximum 1
Voltage Between P2_G (female) (C) and ground
V

14 Between ECM2 J1 (female) (78) and (18), or between Minimum 1
ness
P2_G (female) (A) and (B) MΩ
Resistance
Between ECM2 J1 (female) (54) and (18), or between Minimum 1
P2_G (female) (B) and (B) MΩ
40-568 HD465-8, HD605-8


If no failure was found with these procedures, the engine Bkup speed sensor may be
REMARK
15 q
HD465-8, HD605-8 40-569

40-570 HD465-8, HD605-8


Action level Failure code Sensor Supply_2 Voltage Low Error_2
Failure
Details of fail-
ure
q Runs the engine with the value obtained before the failure occurred, and ignores the signal from the sen-
Procedure of
sor of the doser fuel pressure.
controller
mation q After the repair is completed, remove the failure code by these procedures.

connector

2. Disconnect these connectors one by one, and turn the start switch to ON position.
to 3 until you make sure that all the defective devices that caused the failure are found.
Defective sensor or wiring REMARK
2
harness
Ignore other failure codes caused by the disconnected connectors.
AFT2_PFUE
Connector L
HD465-8, HD605-8 40-571


Action level Failure code Sensor Supply_2 Voltage High Error_2
Failure
Details of fail-
ure
q Runs the engine with the value obtained before the failure occurred, and ignores the signal from the sen-
Procedure of
sor of the doser fuel pressure.
controller

connector

Defective sensor or wiring REMARK
2
harness
AFT2_PFUE
Connector L
40-572 HD465-8, HD605-8


Action level Failure code NE Speed Sensor Supply Voltage Error_2
Failure
Details of fail-
Error occurs in NE speed sensor power supply (5 V) circuit.
ure
Procedure of
Control the engine by Bkup speed sensor signal.
controller
q Engine stops during operation (when Bkup (G) speed sensor is also defective).
Machine Event
q When the engine is stopped, the engine will not start (when Bkup (G) speed sensor is also defective.)

connector

2 REMARK
harness
NE speed sensor NE
Connector
HD465-8, HD605-8 40-573

40-574 HD465-8, HD605-8


Action level Failure code NE Speed Sensor Supply Voltage High Error_2
Failure
Details of fail-
High voltage is generated in power supply (5 V) circuit of NE speed sensor.
ure
Procedure of
Control the engine by Bkup speed sensor signal.
controller
q Engine stops during operation (when Bkup (G) speed sensor is also defective).
Machine Event
q When the engine is stopped, the engine will not start (when Bkup (G) speed sensor is also defective.)

connector

2 REMARK
harness
NE speed sensor NE
Connector
HD465-8, HD605-8 40-575


Action level Failure code IMV or PCV 1 Short Circuit Error_2
Failure
Details of fail-
Supply pump P2_PCV1 circuit has short circuit.
ure
Procedure of
Stops the drive of P2_PCV1.
controller
Machine Event
q The engine is hard to start

connector

2. Disconnect connector P2_PCV1, and connect the socket to male side.
2 Between P2_PCV1 (male) (1) and (2) 2.3 to 5.3 Ω
P2_PCV1
Resistance Minimum 1
Between P2_PCV1 (male) (1) and ground
MΩ

female side.
3 Minimum 1
ness Between ECM2 J1 (female) (23) and ground
MΩ
Resistance
Minimum 1
Between ECM2 J1 (female) (24) and ground
MΩ

2. Insert T-adapter into connector ECM2 J1.
4
harness
Maximum 1
Voltage Between ECM2 J1 (24) and ground
V

Short circuit in wiring har- 2. Disconnect connector ECM2 J1, and connect T-adapter to female side.
5
tor)
40-576 HD465-8, HD605-8

Circuit Diagram related to fuel supply pump PCV1
HD465-8, HD605-8 40-577


Action level Failure code IMV or PCV 1 Open Circuit Error_2
Failure
Details of fail-
Supply pump P2_PCV1 circuit has open circuit.
ure
Procedure of
None in particular
controller
Machine Event

connector

P2_PCV1
MΩ

Open circuit in wiring har- 2. Disconnect connector ECM2 J1, and connect T-adapter to female side.
3
tor)
40-578 HD465-8, HD605-8


Action level Failure code PCV_2 Short Circuit Error_2
Failure
Details of fail-
Supply pump P2_PCV2 circuit has short circuit.
ure
Procedure of
Stops the drive of P2_PCV2.
controller
Machine Event

connector

P2_PCV2
MΩ

female side.
3 Minimum 1
ness Between ECM2 J1 (female) (14) and ground
MΩ
Resistance
Minimum 1
Between ECM2 J1 (female) (48) and ground
MΩ

2. Insert T-adapter into connector ECM2 J1.
4
harness
Maximum 1
Voltage Between ECM2 J1 (48) and ground
V

Short circuit in wiring har- 2. Disconnect connector ECM2 J1, and connect T-adapter to female side.
5
tor)
HD465-8, HD605-8 40-579

40-580 HD465-8, HD605-8


Action level Failure code PCV_2 Open Circuit Error_2
Failure
Details of fail-
Supply pump P2_PCV2 circuit has open circuit.
ure
Procedure of
None in particular
controller
Machine Event

connector

P2_PCV2
MΩ

3
tor)
HD465-8, HD605-8 40-581


Action level Failure code Engine Controller Internal Abnormality_2
Failure
Details of fail-
Internal defect is sensed in the engine controller.
ure
Procedure of
None in particular
controller
Engine operates as normal, however, the engine may stop operation or not be able to be started after it is
Machine Event
stopped.
Related infor-
mation

connector
Battery voltage (for each battery) Min. 12 V
2 Defective battery Battery voltage (2 cells in-line) Min. 24 V
Minimum
1.26

Between E01 terminal and Engine rotation: Medium or 26.0 to 30.5
Voltage
ground higher. V
40-582 HD465-8, HD605-8

HD465-8, HD605-8 40-583

40-584 HD465-8, HD605-8


Action level Failure code Sensor Supply 1 Voltage Low Error_2
Failure
Details of fail-
Low voltage is generated in sensor 1 power supply (5 V) circuit.
ure
q Ignores signal from the Bkup speed sensor, and the engine controller operates using the signal from the
Procedure of
NE speed sensor.
controller

connector

2 REMARK
harness
Bkup speed sensor P2_G
Connector
HD465-8, HD605-8 40-585

40-586 HD465-8, HD605-8


Action level Failure code Sensor Supply 1 Voltage High Error_2
Failure
Details of fail-
ure
q Ignores signal from the Bkup speed sensor, and the engine controller operates using the signal from the
Procedure of NE speed sensor.

connector

2 REMARK
harness
Bkup speed sensor P2_G
Connector
HD465-8, HD605-8 40-587

40-588 HD465-8, HD605-8


Action level Failure code Power Voltage Low Error_2
Failure
Details of fail-
Low voltage is generated in the engine controller power supply circuit.
ure
Procedure of
Operates the engine with power supply voltage at fixed value approximately 6 V.
controller
Phenomenon Engine operates as normal, however, the engine may stop operation or not be able to be started after it is
on machine stopped.
Related infor-
mation

connector
Minimum 12
V
V
Minimum
1.26

Voltage
ground higher. V
HD465-8, HD605-8 40-589

40-590 HD465-8, HD605-8

HD465-8, HD605-8 40-591


Action level Failure code Power Voltage High Error_2
Failure
Details of fail-
High voltage (Min. 36 V) is generated in the engine controller power supply circuit.
ure
Procedure of
Operates the engine with power supply voltage at a set value, approximately 36 V.
controller
Engine operates as normal, however, the engine may stop operation or not be able to be started after it is
Machine Event
stopped.
Related infor-
mation

connector
Minimum 12
V
V
Minimum
1.26

Voltage
ground higher. V
40-592 HD465-8, HD605-8

HD465-8, HD605-8 40-593

40-594 HD465-8, HD605-8


Action level Failure code Engine NE Speed Sensor Error_2
Failure
Details of fail-
Error occurs in the signal from engine NE speed sensor.
ure
Procedure of
Operates the engine by Bkup speed sensor signal.
controller
Machine Event When the engine is in operation, control of supply pump-B stops (when the Bkup speed sensor fails.)
q If failure code [CB238] or [CB239] is shown, troubleshoot for it first.
q Engine speed can be checked by the monitoring function. (Code: 01002)
Related infor-
q The speed sensor senses holes in the flywheel to calculate engine speed.
mation

connector

female side.
Maximum 1
2 Ω
ness
Maximum 1
Ω
Maximum 1
Ω

3
Resistance
(female) (3) MΩ

4
harness
Maximum 1
V

2. Disconnect connectors ECM1 J1, ECM2 J1, and NE, and connect T-adapter to either
female side.
5 Between ECM1 J1 (female) (79) and ECM2 J1 (31), or Minimum 1
ness
between NE (female) (1) and (3) MΩ
Resistance
wheel
HD465-8, HD605-8 40-595


(loose).
installation
REMARK
8 q
40-596 HD465-8, HD605-8


Action level Failure code Engine Controller Internal Temperature Sensor High Error_2
Failure
Details of fail-
High voltage error is generated in signal circuit of the engine controller internal temperature sensor.
ure
Procedure of
None in particular
controller
Procedure: Turn the start switch to the ON the position.

1 Incorrect use of controller Check if the controller is used in high temperature environment.
HD465-8, HD605-8 40-597


Action level Failure code Engine Controller Internal Temperature Sensor Low Error_2
Failure
Details of fail-
Low voltage Fault is detected in signal circuit of engine controller internal temperature sensor.
ure
Procedure of
None in particular
controller
Procedure: Turn the start switch to ON the position.

1 Incorrect use of controller Check if the controller is used in high temperature environment.
40-598 HD465-8, HD605-8


Action level Failure code Engine Backup Speed Sensor Phase Error_2
Failure
Details of fail- Engine controller senses phase error of signal from the Bkup speed sensor of the engine. (Compared with
ure the signal from the NE speed sensor, the phase does not match.)
Procedure of
Controlled by the signal from the engine NE speed sensor.
controller
Machine Event When the engine is in operation, control of supply pump-B stops (when the Bkup speed sensor fails.)
q The speed sensor senses holes in the flywheel to calculate engine speed.
Related infor-
mation

connector

female side.
Maximum 1
2 Ω
ness
Maximum 1
Ω
Maximum 1
Ω

3
Resistance
(female) (3) MΩ

4
harness
Maximum 1
V

2. Disconnect connectors ECM1 J1, ECM2 J1, and NE, and connect T-adapter to either
female side.
5 Between ECM1 J1 (female) (79) and ECM2 J1 (31), or Minimum 1
ness
between NE (female) (1) and (3) MΩ
Resistance
wheel
HD465-8, HD605-8 40-599


(loose).
installation
REMARK
8 q


each female side.
Maximum 1
10 Ω
ness
Maximum 1
Ω
Maximum 1
Ω

11
ness
Resistance
(female) (C) MΩ

harness
Maximum 1
V

2. Disconnect connectors ECM2 J1 and P2_G_RES, and connect T-adapter to female
side of ECM2 J1 or P2_G.
ness
P2_G (female) (A) and (B) MΩ
Resistance
P2_G (female) (B) and (B) MΩ
14
(mounted loosely)
Defective engine Bkup If no failure was found with these procedures, the engine Bkup speed sensor may be
15
speed sensor defective. (Since this is an internal problem, you cannot troubleshoot.)
If no failures is found with these procedures, the Bkup speed sensor of the engine may be
40-600 HD465-8, HD605-8

HD465-8, HD605-8 40-601


Action level Failure code Engine Backup Speed Sensor Error_2
Failure
Details of fail-
Error is detected in engine Bkup speed sensor circuit.
ure
Procedure of
Uses a signal from the NE speed sensor to operate the engine.
controller
q When the engine is in operation, control of supply pump-B stops (when the Bkup speed sensor fails.)
Machine Event
q Engine is hard to start (when the NE speed sensor is normal).
q Since the inner side of the speed sensor has electrical circuits and not coils, you cannot measure the
speed sensor resistance with a multi-meter.
Related infor-
mation

connector


each female side.
Maximum 1
3 Ω
ness
Maximum 1
Ω
Maximum 1
Ω

4
ness
Resistance
(female) (C) MΩ

harness
Maximum 1
V
40-602 HD465-8, HD605-8


ness
P2_G (female) (A) and (C) MΩ
Resistance
P2_G (female) (B) and (C) MΩ
7
(mounted loosely)
If no failure was found with these procedures, the engine Bkup speed sensor may be
REMARK
8 q
Circuit diagram related to engine Bkup speed sensor
HD465-8, HD605-8 40-603


Action level Failure code Engine Controller Partial Data Lost Error_2
Failure
Details of fail-
Internal defect is sensed in the engine controller.
ure
Procedure of
None in particular
controller
q Engine operates as normal, however, the engine may stop operation or not be able to be started after
Machine Event it is stopped.
q Engine controller cannot keep the internal data correctly.
q Engine controller internal data (KDPF data etc.) may be lost. Proper remedy is required after resetting
the error.
NOTICE
Related infor- Procedures after you remove Faults
mation Perform "Active Regeneration for Service". For details, see TEST AND ADJUST, "SERVICE MODE"
and "PROCEDURE TO OPERATE REGENERATION FOR SERVICE TEST MENU" under "SET AND
Procedure: Turn the start switch to ON position.

connector
Minimum 12
V
V
Minimum
1.26

Voltage
ground higher. V
The battery disconnect switch does not operate correctly.
Defective battery discon-
4 nect switch, it does not
REMARK
operate correctly. This failure code is displayed when the power supply is shut down by using the battery
disconnect switch before the engine controller is normally shut down.
40-604 HD465-8, HD605-8

HD465-8, HD605-8 40-605

40-606 HD465-8, HD605-8


Action level Failure code Multi-controller ID Harness Key Error_2
Failure
Details of fail-
The values between the controller and the ID harness are not the same.
ure
Procedure of
Stops the action.
controller
Machine Event When the start switch is in the ON position: Engine will not started.

1
ness Maximum 1
Resistance Between ECM2 J2 (female) (62) and (90)
Ω
Circuit diagram related to engine starting circuit
HD465-8, HD605-8 40-607


Action level Failure code KDOC Abnormality_2
Failure
Details of fail- KDOC inlet and outlet temperature sensors show almost same temperature (difference in temperature is in
ure approximately 10 °C).
q If the failure code [CB3313], [CB3314], or [CB3315] is shown, KDOC inlet the temperature sensor may
be defective. Troubleshoot for [CB3313], [CB3314], or [CB3315].
q If the failure code [CB3316], [CB3317], or [CB3318] is shown, KDOC outlet temperature sensor may be
defective. Troubleshoot for [CB3316], [CB3317], or [CB3318].
Related infor- removed. (This derate is not stopped when you only remove the failure code.)
mation NOTICE
1. Make sure the KDPF is correctly attached to the exhaust system.

1 Defective KDOC
2. Make sure the KDOC is correctly attached to KDPF.

k Put the machine on a level ground, set the park brake switch to the "PARK" position, and chock the tires.
3. Set the park brake switch to the "TRAVEL" position.
NOTICE
40-608 HD465-8, HD605-8

4. Check KDOC inlet temperature and KDOC outlet temperature with monitoring function, and run the engine with depressing
the brake pedal at high idle speed (approximately 2270 rpm) until both temperatures reach 200 °C or higher.
REMARK
NOTICE
KDOC inlet temperature of 250 °C or higher is required to remove the failure code.
5. After both KDOC inlet temperature and KDOC outlet temperature reach 200 °C or higher, continuously run the engine at
high idle speed for another 15 minutes.
REMARK
q If this failure code is not removed, go back to the troubleshooting.
Circuit diagram related to KDOC temperature sensor
HD465-8, HD605-8 40-609


Action level Failure code Defective Regeneration_2
Failure
KDOC efficiency (catalysis) decreases. (Soot in KCSF does not burn normally, because KDOC outlet tem-
Details of fail-
perature does not rise, compared to the normal temperature of 250 to 400 °C for KDOC inlet temperature,
ure
and 450 to 600 °C for KDOC outlet temperature during the regeneration.
Procedure of
controller
q All, the KDOC inlet, the KDOC outlet and KDPF outlet temperatures during idle (non-regeneration) are
100 to 250 °C. Each temperature difference is approximately 10 °C. (KDOC inlet temperature > KDOC
outlet temperature > KDPF outlet temperature).
q During normal manual stationary regeneration, KDOC inlet temperature is 250 to 400 °C. The two
KDOC outlet temperature and KDPF outlet temperature are 450 to 600 °C.
q During manual stationary regeneration without doser fuel injection (dry KDOC). The KDOC inlet, KDOC
Related infor- outlet, and the KDPF outlet temperatures are at 250 to 400 °C.
mation q When Failure code [CB2637] is shown at the same time, troubleshoot for this failure code.
q When soot accumulation level is 3 and below, preform Manual stationary regeneration only from the Ac-
tive Regeneration for Service.
q Repair complete check: When KDOC is not replaced, start the engine and perform the manual station-
ary regeneration.
NOTICE
q When KDOC is replaced, the repair completed check is not required.
q If KDOC of KDPF is replaced, perform the setting after KDOC is changed, then repair is complete.

REMARK
temperature sensor
ASSEMBLY".
REMARK
To test the exhaust gas color, See TEST AND ADJUST, "TEST EXHAUST GAS
2
color If excess black smoke is seen at high idle or when the engine accelerates, perform "KDPF
GETS CLOGGED IN A SHORT TIME".
REMARK
If black smoke comes out when the engine accelerates, but disappears at high idle, there
is no problem.
40-610 HD465-8, HD605-8

1. Remove KDPF.
2. Remove KDOC.
KDOC.
Defective KDOC
damage)
REMARK
The failure codes [CB1691] and [CB2637] do not appear after KDPF Memory setting is
performed. At this point, the procedure to prevent fuel dose injection is stopped, which
Defective KDOC (lowered 7. Start the engine, and perform manual stationary regeneration. When the failure code
4
KDOC function) does not appear, perform KDPF Memory Reset and complete the troubleshooting.
8. If the failure code [CB2637] is shown after you complete manual stationary
regeneration, KDOC is defective. (Catalysis function of KDOC is lowered.
Replace KDOC.)
REMARK
The failure codes [CB1691] and [CB2637] do not appear after KDPF Memory setting is
performed. At this point, the procedure to prevent fuel dose injection is stopped, which
HD465-8, HD605-8 40-611


Action level Failure code Sensor Supply 5 Voltage High Error_2
Failure
Details of fail- High voltage error occurs in power supply (5 V) of KDPF differential pressure sensor and KDPF outlet pres-
ure sure sensor.
q Controls the KDPF outlet pressure sensor at an estimate value (0 kPa {0 kg/cm2}).
q Controls the KDPF differential sensor at an estimate value (The controller may operate at 0 kPa {0
Procedure of
controller kg/cm2}.)
q Engine derate is stopped when you turn the start switch to the OFF position after this failure code
Related infor- is removed. (This derate is not stopped when you only remove the failure code.)

connector

2. Disconnect camera connector DPFP2, and Turn the start switch to the ON position.
Defective KDPF differen- REMARK
2 tial pressure (outlet pres-
sure) sensor Ignore other failure codes caused by the disconnected connectors.
If this failure code is not shown, KDPF differential pressure (outlet pressure) sensor is
defective.

2. Disconnect connectors ECM1 J2 and DPFP2, and connect T-adapter to either female
3
ness
Between ground and ECM2 J2 (female) (8) or PDPF_2 Minimum 1
Resistance
(female) (4) MΩ

4
ness
Between ECM2_J2 (female) (8) and each pin other than Minimum 1
Resistance
pin (8) MΩ
40-612 HD465-8, HD605-8

HD465-8, HD605-8 40-613


Action level Failure code Sensor Supply 5 Voltage Low Error_2
Failure
Details of fail-
Low voltage error in (5 V) supply of the differential pressure and the outlet pressure sensors of the KDPF.
ure
q Controls the KDPF outlet pressure sensor at an estimate value (0 kPa {0 kg/cm2}).
q Controls the KDPF differential sensor at an estimate value (The controller may control at 0 kPa {0
Procedure of
controller kg/cm2}.)
q Engine derate is stopped when you turn the start switch to the OFF position after this failure code
Related infor- is removed. (This derate is not stopped when you only remove the failure code.)

connector

2. Disconnect camera connector DPFP2, and Turn the start switch to the ON position.
Defective KDPF differen- REMARK
2 tial pressure (outlet pres-
sure) sensor Ignore other failure codes caused by the disconnected connectors.
If this failure code is not shown, KDPF differential pressure (outlet pressure) sensor is
defective.

2. Disconnect connectors ECM2 J2 and DPFP_2, and connect T-adapter to either
3
ness
Between ground and ECM2 J2 (female) (8) or DPFP_2 Minimum 1
Resistance
(female) (4) MΩ

2. Disconnect connectors ECM2 J2 and DPFP_2, and connect T-adapter to female side
4
ness
Between ECM2_J2 (female) (8) and each pin other than Minimum 1
Resistance
pin (8) MΩ
40-614 HD465-8, HD605-8

HD465-8, HD605-8 40-615


Action level Failure code KDPF Differential Pressure Sensor High Error_2
Failure
Details of fail-
High voltage is generated in the signal circuit of KDPF differential pressure sensor.
ure
q Controls the differential pressure sensor of the KDPF at a calculated value. (The controller may operate at
0 kPa if other failure codes are shown at the same time.)
Procedure of
controller
q If the failure code [CB1695] or [CB1696] is also shown, the sensor power supply system may be defec-
tive. Troubleshoot for it first.
q When the failure code [CB1695] is not displayed while at the same time the failure code [CB3133] is
displayed, open circuit may have occurred in GND line (defective contact of the connector).

connector

2. Disconnect the connector DPFP_2.
Defective KDPF differen- 3. Turn the start switch to the ON position.
2
tial pressure sensor
If the failure code [CB1879] changes to [CB1881], the KDPF differential pressure sensor
is defective.

2. Disconnect connectors ECM2 J2 and DPFP_2, and connect T-adapter to each female
3
ness
Maximum 1
Resistance Between ECM2 J2 (female) (32) and DPFP_2 (female) (1)
Ω

2. Disconnect connector DPFP_2, and connect T-adapter to female side.
4
harness
Maximum 1
Voltage Between DPFP_2 (female) (2) and (1)
V

5
ness
pin (41)
40-616 HD465-8, HD605-8


HD465-8, HD605-8 40-617


Action level Failure code KDPF Differential Pressure Sensor Low Error_2
Failure
Details of fail-
Low voltage is generated in the signal circuit of KDPF differential pressure sensor.
ure
Procedure of
controller
q If the failure code [CB1695] or [CB1696] is also shown, the sensor power supply system may be defec-
tive. Troubleshoot for it first.
q When the failure code [CB1696] is not displayed while at the same time the failure code [CB3134] is
displayed, the sensor connector may be disconnected or open circuit may have occurred in 5 V line (de-
fective contact of the connector).

connector

side.
Maximum 1
Open circuit in wiring har- Between ECM2 J2 (female) (32) and DPFP_2 (female) (1)
2 Ω
ness
Maximum 1
Resistance Between ECM2 J2 (female) (8) and DPFP_2 (female) (4)
Ω
Maximum 1
Between ECM2 J2 (female) (41) and DPFP_2 (female) (2)
Ω

3
ness
Between ground and ECM2 J2 (female) (41) or DPFP_2 Minimum 1
Resistance
(female) (2) MΩ

4
ness
pin (41)
40-618 HD465-8, HD605-8


Defective KDPF differen- 2. Insert T-adapter into the connector DPFP_2.
tial pressure sensor
Voltage Between DPFP_2 (2) and (1) 0.5 to 4.5 V
HD465-8, HD605-8 40-619


Action level Failure code KDPF Differential Pressure Sensor In Range Error_2
Failure
Details of fail- Signal voltage from the differential pressure sensor of the KDPF does not show the correct value. (The sig-
ure nal voltage is in normal or in operation range.)
Procedure of q Stops EGR valve operation.
q If failure code [CB1695] or [CB1696] is also shown, the sensor power supply system may be defective.
q To start the engine, wait until the system operation lights is off after you turn the start switch to the OFF
mation q After you investigate the problem, and complete the repair, perform the Loaded Diagnostics Op-

connector
1. Remove the KDPF differential pressure sensor pipe.

2 5. Perform Loaded Diagnostics Operation To Clear Failure Code.
tial pressure sensor pipe.
REMARK
3 KDPF differential pressure ASSEMBLY" and "DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY". Repair as
sensor necessary.
40-620 HD465-8, HD605-8


If the failure code [CB1881] is not displayed, the wiring harness or engine controller is
defective.
REMARK

Defective wiring harness or 2. Disconnect connector DPFP_2, and connect the short socket adapter to female side.
4
engine controller 3. Connect 5 V to the signal line. (Short-circuit pins (4) and (2) of connector DPFP_2.)
REMARK
If failure code [CB1879] is not shown, the wiring harness or engine controller is defective.
REMARK
Defective KDPF differen- If failure codes [CB1881] and [CB1879] display with these procedures, the KDPF differen-
5
tial pressure sensor tial pressure sensor is defective.

(Make sure that the failure code is removed after this procedure.)
REMARK
Perform this to make the engine controller recognize the change in sensitivity of the sensor when the start switch is turned
to the ON position.
2. Turn the start switch to the OFF position to stop the engine.
HD465-8, HD605-8 40-621

NOTICE
REMARK
30100)
REMARK
q If this failure code is not removed, perform steps 4 and 5, three times.
40-622 HD465-8, HD605-8


Action level Failure code KDPF Soot Accumulation High Error 1_2
Failure
The KDPF soot level is 6 or 7, and a very large quantity of soot accumulates. Operator is required to imme-
Details of fail-
diately perform the manual stationary regeneration. (You must replace the KDPF when the soot accumula-
ure
tion increases to level 8.)
Procedure of
controller
q Disables automatic regeneration.
Phenomenon
on machine
k KDOC and KDPF become hot (Minimum 500 °C). Be careful not to become burned.
q During manual stationary regeneration, the KDOC inlet temperature is approximately 250 to 400 °C. The
KDOC and KDPF outlet temperatures are approximately 450 to 600 °C each.
q If another failure code is also shown (which includes manual stationary regeneration), troubleshoot for
it first.
q When the failure code [CB1922] is originally displayed, the cord changes to the failure code [CB1921]
during troubleshooting of [CB1922]. In that case, see failure code [CB1922].
q Soot accumulation level 5: Approximately 1 to 2 hours
q Soot accumulation level 6 or 7: Approximately 2 to 3 hours
Related infor- q Soot accumulation level 8: Manual stationary regeneration cannot be performed.
mation The cause of too much soot accumulation
1. Engine runs in a low load range where the temperature is not hot enough to burn the soot in the KDPF.
q To prevent accumulation of soot in the KDPF, operate the engine in a high load condition.
2. There is an engine failure when too much black smoke is generated.
3. Regeneration Disable is set on the monitor screen.
q Regeneration is set not to be performed automatically, even if soot accumulates. Cancel Regener-
ation Disable in a safe place to perform the regeneration, as it is required.
How to cancel the Regeneration Disable
Select Cancel the Regeneration Disable from Aftertreatment Devices Regeneration in the user menu, and
perform it. (For details, see Operation and Maintenance Manual, "Handle", "Procedures for Aftertreatment
Devices Regeneration Disable" see "Handle the KDPF".)
1. Make sure the Regeneration Disable button is not pushed on the machine monitor. (If
pushed, cancel the Regeneration Disable.)
4. If manual stationary regeneration from the user mode is completed, the repair is
Defective soot accumula- completed.
1
tion level of KDPF (KCSF) If the regeneration is not completed in 3 hours, perform troubleshooting for failure
code [CB2639].
5. Make sure that the failure code is removed after the manual stationary regeneration is
completed.
6. If the failure code [CB1921] or [CB2639] is displayed after manual stationary regener-
ation is completed, test the exhaust gas color.
HD465-8, HD605-8 40-623


q Test the exhaust gas color if the failure code [CB1921] or [CB2639] is displayed after
the manual stationary regeneration is completed.
q To test the exhaust gas color, See TEST AND ADJUST, "TEST EXHAUST GAS COL-
OR".
q Perform the Regeneration Disable on the machine monitor when test the exhaust gas
Defective exhaust gas color.
2
color 1. Quickly accelerate the engine from low idle to high idle twice, and then hold at high
idle for 5 seconds. If black smoke comes out at high idle during acceleration, trouble-
shoot for "KDPF GETS CLOGGED IN A SHORT TIME" in S mode. If black smoke
comes out at acceleration but disappears at high idle speed, there is no problem.
2. To complete the exhaust gas color test, cancel the Regeneration Disable.
3. Make sure that there is no failure code is shown.
40-624 HD465-8, HD605-8


Action level Failure code KDPF Soot Accumulation High Error 2_2
Failure
q A large quantity of soot accumulates in KDPF. Stop the engine immediately and perform an inspection
Details of fail-
and maintenance.
ure
q Soot accumulation gets level 8. (KDPF is completely clogged with soot.)
Procedure of
controller
q Disables automatic regeneration, disables manual stationary regeneration
q If the failure code [CB3316], [CB3317], or [CB3318] display, the KDOC outlet temperature sensor may
Related infor- Time required to complete manual stationary regeneration varies by the quantity of soot accumulated in the
mation KCSF as described below.
q Soot accumulation level 8: Manual stationary regeneration prevented.
REMARK
If the soot accumulation level is 8, you need to check, clean or replace because KDPF is completely
clogged with soot.
Increased soot accumula- Make sure that the regeneration disable button is not pushed on the machine monitor.
1 tion because of stopped REMARK
regeneration If it is pushed, it stops the Regeneration Disable.
HD465-8, HD605-8 40-625


2. Make sure that failure codes [CB2639], [CB1921], and [CB1922] display on the Abnor-
mality Record screen of the machine monitor.
Time period from when the failure code [CB2639] is displayed till when [CB1921] is dis-
played ≥ 360 sec. (KOMTRAX record) or ≥ 0.1 h (monitor record screen), and time period
from when [CB1921] is displayed till when [CB1922] is displayed ≥ 360 sec.
(KOMTRAX record) or ≥ 0.1 h (monitor record screen)
When these conditions are met:
REMARK
Because accumulated soot quantity is high, KDPF regeneration is prevented.
1. Replace the KCSF or KDPF.
2. Turn the start switch to the ON position, and set the KDPF after it is clean. (See
PRECAUTIONS TO CLEAN AND REPLACE THE KDPF (KCSF and KDOC).)
Defective KDPF (KCSF) q Make sure that the displayed failure code changes from[CB1922] to [CB1921].
2
(KCSF replacement) q If failure code [CB1922] persists, examine the operation procedure for KDPF
Memory Reset, and then clean the KDPF again.
3. Set the Clean the KDPF. (See PRECAUTIONS TO CLEAN AND REPLACE KDPF
(KCSF and KDOC).)
4. Check for defective KDPF differential pressure sensor.
7. If manual stationary regeneration from Active Regeneration for Service is completed
to remove moisture from KCSF, the repair is completed.
q If the regeneration is not completed in 3 hours, troubleshoot for the failure code
[CB2639]. Make sure that the failure code is removed after the manual stationary
regeneration. If failure code [CB1922], [CB1921], or [CB2639] are displayed, test
the exhaust gas color.
When the above condition is not met:
The actual accumulation of soot is less than the indicated value.
If the actual accumulation of soot is less than the indicated value on the machine monitor:
2. Turn the start switch to the ON position, and clean the KDPF. (See PRECAUTIONS
TO CLEAN AND REPLACE KDPF (KCSF and KDOC).)
q Make sure that the displayed failure code changes from[CB1922] to [CB1921].
q If failure code [CB1922] persists, examine the operation procedure for KDPF
Memory Reset, and then clean the KDPF again. (See PRECAUTIONS TO CLEAN
AND REPLACE KDPF (KCSF and KDOC).)
NOTICE
Do not reset KDPF Change if KCSF or KDPF is not replaced.
Defective KDPF (KCSF)
3 (abnormal soot accumula- 3. Start the engine.
tion) 4. Secure the machine in a safe area.
5. If manual stationary regeneration from the user mode is completed, the repair is
completed.
q If failure code [CB1922] shows again in 1 hour after the manual stationary regen-
eration started, troubleshoot for cause 1, Increased soot accumulation because of
stopped regeneration. Troubleshoot cause 2, Defective KDPF (KCSF) (KCSF re-
placement)
q If the regeneration is not completed in 3 hours, troubleshoot for failure code
[CB2639]. Make sure that the failure code is removed after the manual stationary
regeneration. If the failure codes [CB1922], [CB1921], or [CB2639] show, test the
exhaust gas color.
40-626 HD465-8, HD605-8


Clean the pipe of the KDPF
4 differential pressure sensor
pipe. 4. Install the KDPF differential pressure sensor pipe with the two pipes connected
correctly.
5. Perform Loaded Diagnostics Operation To Confirm Failure Correction.
q If the failure code [CB1921] or [CB2639] is shown after manual stationary regenera-
tion is completed, test the exhaust gas color.
q To test the exhaust gas color, See TEST AND ADJUST, "TEST EXHAUST GAS COL-
OR".
q Perform the Regeneration Disable on the machine monitor when test the exhaust gas
Defective exhaust gas color.
5
color 1. Quickly accelerate the engine from low idle to high idle twice, and then hold at high
idle for 5 seconds. If black smoke comes out at high idle during acceleration, trouble-
shoot for "KDPF GETS CLOGGED IN A SHORT TIME" in S mode. If black smoke
comes out at acceleration but disappears at high idle speed, there is no problem.
2. To complete the exhaust gas color test, cancel the Regeneration Disable.
3. Make sure that there is no failure code is shown.
HD465-8, HD605-8 40-627


Action level Failure code Fuel Doser Solenoid 1 High Error_2
Failure
Details of fail-
High-voltage error is sensed in circuit of the fuel doser solenoid valve 1 (shut off valve).
ure
Procedure of
controller
Machine Event
k Exhaust connector and KDPF become hot (Minimum 500 °C). Be careful not to become burned.
q When the failure code [CB2732] is also displayed, open circuit may have occurred in GND line.

connector

2
Resistance

female side.
REMARK
Open circuit in wiring har- When the failure code [CB2732] is also displayed, open circuit may occur in GND line.
3
ness
Between ECM2 J1 (female) (8) and AFT2_SOV1 (female) Maximum 1
(1) Ω
Resistance
(2) Ω

2. Disconnect connector AFT2_SOV1, and connect T-adapter to female side.
4
harness
Maximum 4.7
Voltage Between AFT2_SOV1 (female) (1) and (2)
V
40-628 HD465-8, HD605-8

HD465-8, HD605-8 40-629


Action level Failure code Fuel Doser Solenoid 1 Low Error_2
Failure
Details of fail-
Low voltage error is sensed in the solenoid valve (shut off valve) 1 circuit of the fuel doser.
ure
Procedure of
controller
Machine Event
Related infor- q This failure code stops after the failure is eliminated. Then solenoid valve 1 of the fuel operates again
mation when you cycle the start switch to the ON and then to the OFF position.

connector

2
Resistance

female side.
3 Between ECM2 J1 (female) (8) and AFT2_SOV1 (female) Maximum 1
ness
(1) Ω
Resistance
(2) Ω
1. Turn the start switch to the OFF the position.

4
ness
Between ground and ECM2 J1 (female) (9) or AFT2_SOV2 Minimum 1
Resistance
(female) (1) MΩ
1. Turn the start switch to the OFF the position.

5
ness
pin (8)
40-630 HD465-8, HD605-8


1A. Fuel doser-A
1B. Fuel doser-B
3A. Fuel doser solenoid valve 1-A (SHUTOFF valve)
3B. Fuel doser solenoid valve 1-B (SHUTOFF valve)
a: From fuel pump-A
b: From fuel pump-B
c: Fuel return
e: From the fuel supply pump
tor
HD465-8, HD605-8 40-631


Action level Failure code Fuel Doser Solenoid 1 In Range Error_2
Failure
Details of fail- Valve 1 for the Fuel doser solenoid does not operate correctly. (Dosing fuel pressure is sufficiently lowered
ure because the valve on the fuel inlet side is opened when the correct position is closed.)
Procedure of
controller
Machine Event
q If the failure code [CB1927] or [CB1928] is shown, the pressure sensor for the fuel doser may be defec-
Related infor- tive. Troubleshoot for it first.
Procedure: Turn the start switch from the OFF to the ON position to start the engine. Run the engine at
low idle for approximately 3 minutes.

connector

2. Disconnect fuel supply line (2B) from fuel doser (1B).
3. Disconnect connector AFT2_SOV1.
4. Replace fuel doser solenoid valve 1-B (shut-off valve) (3B).
Defective doser fuel shut 5. Connect disconnected connector AFT2_SOV1 to the replaced fuel doser solenoid
2 valve1-B (shut-off valve) (3B).
off valve
If fuel leaks from the fuel connector to the fuel supply line (2B), the fuel doser solenoid
valve 1-B (SHUTOFF valve) (3B) is defective.
40-632 HD465-8, HD605-8


1A. Fuel doser-A
1B. Fuel doser-B
a: From fuel pump-A
b: From the fuel pump-B
c: Fuel return
d: To fuel the supply pump
e: From the fuel supply pump
tor
HD465-8, HD605-8 40-633


Action level Failure code Dosing Fuel Pressure Sensor High Error_2
Failure
Details of fail-
Sensor voltage from fuel doser pressure sensor is higher than specified limits.
ure
Action of con-
troller
q If failure codes [CB187] or [CB227] display, the sensor power supply may be defective, troubleshoot
them first.
(Code: 47602)
Procedure: Turn the start switch to the ON position. (Examine the condition for 1 minute.) (Because of
L01, examine the Abnormality Record screen also.)
No. Cause Procedures, test location, specifications and remarks.

1 harnesses and connectors in the table "Electric equipment" in "CHECKS BEFORE
connector

Defective Fuel doser pres- 2. Disconnect the connector AFT2_PFUEL.
sure sensor
If failure code [CB1927] changes to [CB1928], the fuel doser pressure sensor is defective.

2. Disconnect connectors ECM2 J1 and AFT2_PFUEL, and connect T-adapter to each
3
ness
(female) (2)

Hot short circuit in wiring 2. Disconnect connector AFT2_PFUEL, and connect T-adapter to female side.
harness
Voltage Between AFT2_PFUEL (female) (3) and (2) Max. 1 V

2. Disconnect connectors ECM2 J1 and AFT2_PFUEL, and connect T-adapter to female
5
ness
pin (57)
If no failures are found with these procedures, the engine is controller defective. (Since
40-634 HD465-8, HD605-8

Circuit Diagram related to fuel doser pressure sensor
HD465-8, HD605-8 40-635


Action level Failure code Dosing Fuel Pressure Sensor Low Error_2
Failure
Details of fail-
Sensor voltage from the fuel doser pressure sensor is lower than specified limits.
ure
Action of con-
troller
Effect to the q Automatic regeneration is not performed.
k Exhaust connector and KDPF become hot (Min. 500 °C). Be careful not to get burned.
q If failure codes [CB187] or [CB227] display, the sensor power supply may be defective, troubleshoot
them first.
(Code: 47602)
Procedure: Turn the start switch to the ON position. (Examine the condition for 1 minute.) (Because of
L01, examine the Abnormality Record screen also.)

connector

2. Disconnect connectors ECM2 J1 and AFT2_PFUEL, and connect T-adapter to each
female side.
2 (female) (1)
ness
(female) (2)
Max. 1 Ω
(female) (3)

2. Disconnect connectors ECM2 J1 and AFT2_PFUEL, and connect T-adapter to either
3
ness
AFT2_PFUEL (female) (3)

2. Disconnect connectors ECM2 J1 and AFT2_PFUEL, and connect T-adapter to female
4
ness
pin (57)

Defective Fuel doser pres- 2. Insert T-adapter into connector AFT2_PFUEL.
sure sensor
Voltage Between AFT2_PFUEL (3) and (2) 0.5 to 4.5 V
40-636 HD465-8, HD605-8


Circuit Diagram related to fuel doser pressure sensor
HD465-8, HD605-8 40-637


Action level Failure code Fuel Doser Solenoid 1 Servo Error_2
Failure
Details of fail- Pressure sensed by the fuel doser pressure sensor is lower than specified limits while the fuel doser sole-
ure noid valve 1 is ON.
Action of con-
troller
q If failure codes [CB1923], [CB1924], or [CB1925] display, the fuel doser solenoid valve 1 may be defec-
tive, troubleshoot them first
q If failure codes [CB2732] or [CB2733] display, the fuel doser solenoid valve 2 may be defective, trouble-
shoot them first.
q If failure codes [CB1927] or [CB1928] display, the fuel doser pressure sensor may be defective, trouble-
Related infor- shoot them first.
mation q If failure code [CA559] display, the Fuel supply pump may be defective, troubleshoot it first.
q If failure codes [CB2265] or [CB2266] display, fuel pump may be defective, troubleshoot them first.
Turn the start switch from OFF to the ON position to start the engine. When the failure code is cleared
after you run the engine at low idle for approximately 3 minutes, the repair is completed.
q After the repair is completed, make sure the failure code is removed with these procedures.

1 harnesses and connectors in the table "Electric equipment" in "CHECKS BEFORE TROU-
connector
BLESHOOTING" under "RELATED INFORMATION ON TROUBLESHOOTING", and
check the connectors.
2 Clogged fuel filter Check the fuel filter for clogging.
Check if No.8 in fuse box BT2 is blown out.
Defective fuse for fuel feed
3
pump
REMARK
If blown out, perform troubleshooting for ground fault in wiring harness.

OFF position.
5. Turn starting switch to ON position.
Voltage
4
ness 1. Turn starting switch to OFF position.
OFF position.
Between EPTS (female) (3) and BT2-16 Max. 1 Ω
Between EPTS (female) (3) and (4) Max. 1 Ω
Resistance
40-638 HD465-8, HD605-8


Ground fault in wiring har- OFF position.
5 3. Disconnect connector EPTS, and connect T-adapter to female side.
ness
4. Remove fuse No.8 in fuse box BT2.
Resistance Between ground and EPTS (female) (3) Min. 1 MΩ

2. Loosen the fuel tube joint bolt (JB).
3. Tilt the switch for the fuel feed pump to ON position while the starting switch is in OFF
position.
Defective fuel feed pump k Fuel may spurt out. So be careful.
6
system
4. Set the switch for the fuel feed pump to OFF position and finish the test.
If fuel does not come out from the joint bolt (JB) of fuel tube, perform troubleshooting for
"FUEL FEED PUMP DOES NOT OPERATE OR DOES NOT STOP AUTOMATICALLY"
in E mode.

2. Disconnect the fuel supply line-B (2B) from fuel doser-B (1B).
Defective Fuel doser pres-
7 4. See RELATED INFORMATION TO TROUBLESHOOT to see the doser fuel pressure
sure sensor
and ambient pressure at the same time on the machine monitor.
If the fuel doser pressure and ambient pressure are different, the doser fuel pressure sen-
sor is defective.
8 Replace fuel doser solenoid valve 1-A (shut-off valve).
noid valve1
Start the engine, and leave it for approximately 3 minutes. (Implementation of related
information, "Method of clearing failure code".)
9 Defective engine controller If this failure code is still displayed and no failure is found by preceding checks, engine
controller is defective. (In case of an internal defect, troubleshooting is impossible as an
assembly. Replace whole assembly.)
HD465-8, HD605-8 40-639


1A. Fuel doser-A
1B. Fuel doser-B
a: From fuel pump-A
b: From fuel pump-B
c: Fuel return
tor
40-640 HD465-8, HD605-8

Circuit Diagram related to electric fuel feed pump switch
HD465-8, HD605-8 40-641


Action level Failure code Fuel Doser Open Circuit Error or Short Circuit Error_2
Failure
Details of fail-
Short circuit or open circuit occurs in fuel doser circuit.
ure
Action of con-
troller
47603)
q Pressure detected by the dosing fuel pressure sensor can be checked by the monitoring function.
(Code: 47602)
q The disabled regeneration control is removed when the engine is shutdown, after you turn the start
switch to OFF.
Related infor-
mation
NOTICE
q This failure code requires the "Loaded Diagnostics Operation To Remove the Failure Code". Af-
ter you investigate the problem cause and complete the repair, perform "Loaded Diagnostics
Operation To Clear Failure Code" and make sure the failure code is removed. (This failure code
is not removed when you only turn the start switch to the ON position.)

connector

2. Disconnect connector AFT2_HC_INJ, and connect T-adapter to male side.
Defective fuel doser injec-
2
tor Between AFT2_HC_INJ (male) (1) and (2) 0.5 to 2 Ω
Resistance
Between AFT2_HC_INJ (male) (1) and ground Min. 1 MΩ

2. Disconnect connectors ECM2 J1 and AFT2_HC_INJ, and connect T-adapter to each
female side.
3 Between ECM2 J1 (female) (5) and AFT2_HC_INJ
ness Max. 1 Ω
(female) (1)
Resistance
Between ECM2 J1 (female) (29) and AFT2_HC_INJ
Max. 1 Ω
(female) (2)

2. Disconnect connectors ECM2 J1 and AFT2_HC_INJ, and connect T-adapter to either
4
ness
AFT2_HC_INJ (female) (1)
40-642 HD465-8, HD605-8


Hot short circuit in wiring 2. Disconnect connector AFT2_HC_INJ, and connect T-adapter to female side.
harness
Voltage Between AFT2_HC_INJ (female) (2) and ground Max. 3 V

2. Disconnect connectors ECM2 J1 and AFT2_HC_INJ, and connect T-adapter to
6
ness
pin (5)

Make sure the repair is completed using these procedures.
(Make sure that the failure code is not shown.)
2. Turn the starting switch from OFF to ON position.
3. Start the engine, and perform Active Regeneration for Service.
4. When failure code [CB1977] is cleared, stop the Active Regeneration for Service.
Circuit diagram related to fuel doser (injector)
HD465-8, HD605-8 40-643


Action level Failure code KDPF Differential Pressure Low Error_2
Failure
Details of fail-
Signal voltage from KDPF differential pressure sensor is lower than specified limits.
ure
q Closes EGR valve.
Action of con- q Derates the engine power for operation.
troller q Stops regeneration control.
Effect to the
machine
k KDPF becomes hot (Minimum 500 °C), be careful not to become burned.
q If failure codes [CB1879], [CB1881], or [CB1883] display, the KDPF differential pressure sensor system
may be defective. Troubleshoot them first.
q To start the engine, after you have turned the start switch OFF, wait until the system operation light is
Related infor- OFF. Then turn the start switch to the ON position.
mation NOTICE
q This failure code requires machine operation to remove the failure code. After you investigate
the cause and repair it, perform the Loaded Diagnostics Operation To Remove Failure Code to
make sure the failure code is removed.
1. Turn the start switch to the OFF position, and then turn it to the ON position again.
2. Make sure no other then [CB1993] failure code display.
3. Start the engine, accelerate the engine from low idle to high idle twice, and then hold
1 KCSF Abnormality 1 the engine at high idle for 5 seconds. Examine the exhaust gas color from the exhaust
pipe during the fast acceleration and at high idle.
4. If black smoke comes out of the exhaust pipe, the KCSF is defective. Examine the
KCSF, for damages, or contamination with unwanted materials, and repair as neces-
sary.
1. Remove KDPF differential pressure sensor pipe.

2. Clean and unblock the KDPF differential pressure sensor pipe.
3. Examine the KDPF differential pressure sensor pipe for cracks and damage.
2 5. Perform Loaded Diagnostics Operation To Clear Failure Code.
tial pressure sensor pipe
REMARK
1. Remove KDPF and then remove KCSF to examine the filter in side the KCSF. If it is
3 KCSF Abnormality 2 damaged, or contamination with unwanted materials, then repair the filter.
2. Perform Loaded Diagnostics Operation To Clear Failure Code.
40-644 HD465-8, HD605-8


REMARK
turned to ON position.
5. Stall the torque converter continuously for approximately 1 minute as described below with the accelerator pedal in the
100% open position.
1) Make sure that the park brake switch is set to "PARK" position and set the gear shift lever to the "D" position while you
depress the brake pedal fully.
k Be sure to set the gear shift lever to the "D" position. Because the machine may move, with the brake pedal
depressed if the gear shift lever is set to a position other than "D".
k Make sure you set the gear shift lever to the "D" position while the torque converter is stalled to avoid in-
ternal damage to the transmission.
2) Gradually depress of the accelerator pedal with the brake pedal depressed to stall the torque converter.
NOTICE
REMARK
30100)
REMARK
q If this failure code is not cleared, perform the above steps 4 and 5 for three times.
HD465-8, HD605-8 40-645


Action level Failure code Fuel Feed Pump Open Circuit Error_2
Failure
Details of fail-
Fuel feed pump drive signal circuit is open (when controller drives pump timer switch).
ure
Action of con-
None in particular
troller
Effect on the q While you bleed air, the engine start ability becomes poor.
q This failure code is sensed only when the feed pump is OFF.
Related infor-
mation

connector

Open circuit in wiring har- 2. Disconnect connectors ECM2 J1 and EPTS, and connect T-adapter to each female
2 side.
ness
Resistance Between ECM2 J1 (female) (7) and EPTS (female) (6) Max. 1 Ω

Hot short circuit in wiring 2. Insert T-adapter into the connector EPTS.
harness
Voltage Between EPTS (6) and ground Max. 1 V
Fuel pump is operated during the pressure test immediately after you start the engine.
2. Insert T-adapter into the connector EPTS.
Defective pump timer 4. Start the engine. (Pump timer switch is operated only immediately after start the
4 engine.)
switch
When the pump timer switch
20 to 30 V
Between EPTS (6) and is activated
Voltage
ground When the pump timer switch
Max. 1 V
is stopped
40-646 HD465-8, HD605-8

HD465-8, HD605-8 40-647


Action level Failure code Fuel Feed Pump Short Circuit Error_2
Failure
Details of fail-
Fuel pump control signal circuit short (when the controller operates the pump timer switch).
ure
Action of con-
None in particular
troller
Effect on the q While you bleed air, the engine is hard to start.
q This failure code is detected only when the feed pump is ON.
Related infor- q After the repair is completed, check that the failure code is cleared by the following procedure.
mation 1. Turn the start switch to the OFF position, and stop the engine controller.

connector
2. Disconnect the connector EPTS.
Defective pump timer 4. Start the engine.
2
switch
If this failure code does not display, the throttle sensor is defective.
REMARK

2. Disconnect connectors ECM2 J1 and EPTS, and connect T-adapter to either female
3
ness
Between ground and ECM2 J1 (female) (7) or EPTS
(female) (6)
40-648 HD465-8, HD605-8

HD465-8, HD605-8 40-649


Action level Failure code KDOC Face Plugging_2
Failure
KDOC face is blocked.

q KDOC surface contamination because of the operation conditions, and the catalysis efficiency is de-
Details of fail-
creased (clean the KDOC).
ure
q Deteriorated KDOC because of high temperature, decreased efficiency because of contamination, or
decreased efficiency because of damage (Replace KDOC with a new or used one.)
Action of con-
troller
Effect to the
None in particular
machine
k Exhaust connector of turbocharger, KDOC, and KDPF become hot (Min. 500 °C). Be careful not
to get burned.
q If failure code [CB238*] display, VGT may be defective, troubleshoot it first.
q If the failure code [CB227*] or [CB23**] is displayed, EGR valve may be defective. Perform troubleshoot-
ing for it first.
q If KDOC of KDPF is replaced, perform KDOC change_2, and then complete the repair.
q When the soot accumulation level is 3 and lower, Manual stationary regeneration is performed only from
Related infor- Active Regeneration for Service.
mation q If KDOC efficiency decreases, failure code [AQ10N3] could display after failure code [CB2637] is shown
again and again. If KDOC efficiency is lowered, failure code [CB1691] defective regeneration could
show. To test the exhaust gas color, see TEST AND ADJUST, "TEST EXHAUST GAS COLOR".
Start the engine, perform warm-up operation, and operate the machine in normal work for approximately
3 hours. (The time required for to remove codes will reduce with high exhaust temperature conditions.)
NOTICE
Operate the machine for approximately 3 hours, and make sure that this failure code is removed.
Abnormal turbocharger 1. Remove the turbocharger exhaust connector.

1
exhaust connector 2. Check for oil or fuel stuck to the inner side of the turbocharger exhaust connector.
Defective exhaust connec- Examine the exhaust system between the turbocharger and KDPF for loose or damaged
2
tor or duct to KDPF connectors and pipes.
Quickly accelerate the engine from low idle to high idle twice, and then hold the engine at
high idle for 5 seconds.
REMARK
To examine the exhaust gas color, See TEST AND ADJUST, "TEST EXHAUST GAS
3
color If an excess black smoke is seen at high idle during acceleration, perform KDPF GETS
CLOGGED IN A SHORT TIME.
REMARK
If black smoke in seen during engine acceleration, but disappears at high idle speed,
there is no problem.
40-650 HD465-8, HD605-8

1. Remove KDPF.
2. Remove KDPF.
3. Using air through the KDOC outlet, remove discoloration on the ceramic surface on
the inner side.
4. Examine the KDOC ceramic inner side for cracks.
5. If KDOC is cracked, KDOC is defective (replace KDOC).
Defective KDOC, discol-
4 ored, cracked, or dam-
aged.
REMARK
Failure codes [CB1691] and [CB2637] do not appear after the KDPF Memory is set again.
At this point, the procedure to prevent dosing fuel injection is stopped, which was neces-
sary when this failure code was set.
When you do not replace the KDOC
2. Record the initial value of the KDOC inlet, KDPF outlet temperatures during manual
stationary regeneration, and make sure the KDOC outlet temperature is normal. (See
RELATED INFORMATION TO TROUBLESHOOT.)
5. From the Service Menu on the machine monitor, display Diagnostic Tests screen and
open Active Regeneration for Service, and then perform manual stationary regenera-
tion. (Manual stationary regeneration completes in approximately 40 minutes.)
5
KDOC catalyzer function) does not appear, set the KDPF Memory and then complete the troubleshoot proce-
dures.
8. If failure code [CB2637] is shown after you complete manual stationary regeneration,
the KDOC is defective. (Catalysis function of KDOC is lowered), replace the KDOC.
REMARK
HD465-8, HD605-8 40-651


Action level Failure code Manual Stationary Regeneration Request_2
Failure
q Manual Stationary Regeneration Request prompts the operator to perform a manual stationary regen-
eration, which removes soot more effectively than automatic regeneration. This request is made be-
Details of fail-
cause a larger quantity of soot accumulates in the KCSF/KDPF than the quantity of soot that triggers an
ure
automatic regeneration.
Action of con-
Normal control
troller
Effect on the
None in particular
machine
NOTICE
q Perform manual stationary regeneration when this failure code [CB2639] is shown.
q This failure code is shown during manual stationary regeneration, there is no problem.
q If this failure code remains shown on the machine monitor for several hours after manual sta-
tionary regeneration, troubleshoot.
3. From the Service menu on the machine monitor, display the Diagnostic Tests screen and open Active
Related infor-
Regeneration for Service, and then perform manual stationary regeneration.
mation
q Operate the switches during manual stationary regeneration: push the numeral input switches "1", "2", and
"3" in sequence, while "4" is pushed to switch to the monitor screen.
Time required for manual stationary regeneration varies and depends on the soot accumulation quantity in
the KCSF as described below.
q Soot accumulation level 8: Manual stationary regeneration is prevented.
q If another failure code shows (including manual stationary regeneration), troubleshoot it first.
Increased soot accumula- Make sure that the regeneration disable switch is not pushed on the machine monitor.
1 tion is because regenera- REMARK
tions were stopped. If it is pushed, cancel the regeneration disable function.
When the KDPF cools or there is a difference between the KDOC inlet and outlet temper-
atures at idle replace the KDPF outlet temperature sensor. (non regeneration)
REMARK
perature sensor
q When failure codes [AQ00N3] or [AQ00N4] are shown at an altitude of 3000 m or high-
er, exhaust flow for stationary regeneration may not be enough. You may not be able
Uneven soot accumulation
to perform one of the two aftertreatment systems.
3 at high altitude environ-
q Ten minutes after stationary regeneration starts, examine the values on monitor code
ment
47500 and 47501 Dosing Instant Fuel Consumption. Make sure nether are at 0 (l/hr.).
If one of those is continuously at 0 (l/hr.), replace the two KDPFs.
40-652 HD465-8, HD605-8


q Check VGT for mechanical failure.
q Make sure that there is no unwanted material in the oil inlet of VGT servo.
q Perform manual stationary regeneration. If the KDOC inlet temperature remains at
250 °C or below and VGT solenoid current remains at 1000 mA, the VGT is defective.
4 Defective VGT (Approximate time necessary for manual stationary regeneration depends on the ac-
cumulation of soot. See the failure code [CB2639].)
REMARK
VGT solenoid current can be checked by the monitoring function. (Code: 48800 (mA))
Defective KDPF (KDOC,
5 Troubleshoot, Active Regeneration Takes Time in S mode.
KCSF)
Quickly accelerate the engine from low idle to high idle twice, and then hold the engine at
high idle for 5 seconds.
Defective exhaust gas q If an excess black smoke is seen at high idle during acceleration, perform KDPF
6
color GETS CLOGGED IN A SHORT TIME.
q If black smoke comes out during engine acceleration, but disappears at high idle
speed, there is no problem.
HD465-8, HD605-8 40-653


Action level Failure code Fuel Doser Solenoid_2 High Error_2
Failure
Details of fail-
High voltage error is detected in circuit of fuel doser solenoid valve 2 (drain valve).
ure
Action of con-
troller

connector

Defective fuel doser sole- 3. Turn the start switch to the ON position.
2
noid valve 2
Between AFT2_SOV2 (male) (2) and (1) 4 to 6 Ω
Resistance

female side.
REMARK
Open circuit in wiring har- When the failure code [CB1923] is shown, an open circuit may occur in GND line.
3
ness
Max. 1 Ω
(1)
Resistance
Max. 1 Ω
(2)

Hot short circuit in wiring 2. Disconnect connector AFT2_SOV2, and connect T-adapter to female side.
harness
Voltage Between AFT2_SOV2 (female) (1) and (2) Max. 4.7 V
1. Start the engine and run at low idle for approximately 1 minute.
2. If any other failure codes are shown, troubleshoot those codes.
If the failure code is shown and no failure found with these procedures, the engine control-
ler is defective. (Since this is an internal problem, you cannot troubleshoot.)
40-654 HD465-8, HD605-8

HD465-8, HD605-8 40-655


Action level Failure code Fuel Doser Solenoid_2 Low Error_2
Failure
Details of fail-
Low voltage error is detected in circuit of fuel doser solenoid valve 2-B (drain valve).
ure
Action of con-
troller
Related infor- q This failure code is removed after the problem cause repairs completed. The fuel doser solenoid valve
mation 2 operates again when you turn the start switch to ON and then to the OFF position.
Procedure: start the engine.

connector

Defective fuel doser sole- 3. Turn the start switch to the ON position.
2
noid valve 2
Between AFT2_SOV2 (male) (2) and (1) 4 to 6 Ω
Resistance

3
ness
Between ground and ECM2 J1 (female) (6) or AFT2_SOV2
(female) (1)

4
ness
pin (6)
1. Start the engine and run it at low idle for approximately 1 minute.
40-656 HD465-8, HD605-8

HD465-8, HD605-8 40-657


Action level Failure code Fuel Dozer Solenoid Valve Swap Error_2
Failure
Details of fail- Fuel Doser solenoid valve 1-B (SHUTOFF valve) and fuel doser solenoid valve 2-B (drain valve) are con-
ure nected incorrectly.
Action of con-
troller
Related infor- How to clear the failure code
mation Turn the start switch from OFF to ON and start the engine. When the failure code is removed after you run
the engine at low idle for approximately 3 minutes, the repair is completed.

Reverse connection of wir-
1 Check connectors AFT1_SOV1 and AFT1_SOV2.
ing harness connector

1A. Fuel doser-A
1B. Fuel doser-B
a: From fuel pump-A
b: From fuel pump-B
c: Fuel return
tor
40-658 HD465-8, HD605-8


Action level Failure code Manual Stationary Regeneration Request but KDPF Regeneration
Failure Disable_2
- CB2777 (Engine controller system)
q The Manual Stationary Regeneration Request prompts an operator to perform manual stationary regen-
eration, which removes soot better than automatic regeneration.
Details of fail- This request is made because a larger quantity of soot accumulates in the KDPF than the quantity nec-
ure essary to activate automatic regeneration. However, if the operator set Regeneration Disable, the re-
generation is disabled and the failure code appears.
Action of con-
None in particular
troller
Effect to the
None in particular
machine
k KDOC and KDPF become hot (Min. 500 °C). Be careful not to get burned.
REMARK
The controller attempted to start manual stationary regeneration and regeneration did not start. The KDOC
inlet temperature is below 280 °C and fuel dosing was stopped.
q The KDOC inlet, KDOC outlet, and KDPF outlet temperatures are shown with Pre-defined Monitor
screen.
q During manual stationary regeneration, KDOC inlet temperature is approximately 250 to 400 °C, the
KDOC and KDPF outlet temperatures are approximately 450 to 600 °C.
3. From the Service menu of the machine monitor, display Diagnostic Tests screen and open Active
Regeneration for Service. Remove Regeneration Disable, and then perform manual stationary regen-
eration.
Related infor-
Time required for manual stationary regeneration varies, it depends on the soot accumulation quantity in the
mation
q Soot accumulation level 8: Manual stationary regeneration cannot be performed.
REMARK
q If this failure code remains shown on the machine monitor for several hours after manual stationary re-
generation completes, troubleshoot these.
q If another failure code shows (including manual stationary regeneration), troubleshoot it first.
q This failure code is shown as information to identify a faulty part, not a failure itself.
q If this failure code is frequently shown, request the operator to cancel KDPF Regeneration Disable and
perform manual stationary regeneration. Move the machine to a secure and safe area. Make sure there
are no persons or flammable are near the machine.

If the failure code is not removed after the Regeneration Disable is stopped, the engine
HD465-8, HD605-8 40-659


Action level Failure code Fuel Doser Solenoid 2 Servo Error_2
Failure
q During the pressure test at engine start, the fuel doser solenoid valve 2-B (AFT2_SOV2, drain valve)
ON/OFF command does not match with the estimate fuel pressure sensed by the fuel doser pressure
sensor.
Details of fail-
q When Open AFT2_SOV1 Valve and Close AFT2_SOV2 Valve commands are given, the fuel dosing
ure
pressure sensed by the fuel doser pressure sensor does not increase.
q When Close AFT2_SOV1 Valve and Open AFT2_SOV2 Valve commands are given, the dosing fuel
pressure sensed by the dosing fuel pressure sensor does not decrease.
Action of con-
troller
q If failure codes [CB1923], [CB1924], or [CB1925] display, the fuel doser solenoid valve 1 system may
be defective. Troubleshoot them first.
q If failure codes [CB2732] or [CB2733] display, the fuel doser solenoid valve 2 system may be defective.
Troubleshoot them.
Related infor- q If failure codes [CB1927] or [CB1928] display, the fuel doser solenoid valve 2 system may be defective.
mation Troubleshoot them.
Turn the start switch from OFF to the ON position and start the engine. When the failure code is removed
after you run the engine at low idle for 3 minutes, the repair is completed.
Procedure: start the engine. (Examine the condition for 3 minutes.)

connector

2. Disconnect the connectors AFT2_SOV1 and AFT2_SOV2.
3. Replace fuel doser solenoid valve 1-B with the fuel doser solenoid valve 2-B.
Defective fuel doser sole- REMARK
2
noid valve 2 Do not replace the connector AFT2_SOV1 with AFT2_SOV2.
IF this failure code changes to the code [CB1963], the original fuel doser solenoid valve
2-B is defective.
3 Clogged fuel return pipe Remove the fuel return pipe to check for blockage.
Defective air intake mani- Remove the fuel pipe and examine for a blockage in the fuel connector on the fuel SHUT-
5
fold OFF manifold.

sure sensor
40-660 HD465-8, HD605-8



1A. Fuel doser-A
1B. Fuel doser-B
a: From fuel pump-A
b: From fuel pump-B
c: Fuel return
tor
HD465-8, HD605-8 40-661


Action level Failure code Dosing Fuel Pressure Low Error 1_2
Failure
Details of fail- Pressure sensed by the fuel doser pressure sensor during dosing is below the minimum value, fuel pres-
ure sure is low.
Action of con-
q This effect is cleared when you turn the start switch from OFF to the ON position after the failure code
troller
is shown.
Troubleshoot those.
Troubleshoot those.
Related infor- q If failure code [CA559] display, the fuel supply pump could be defective. Troubleshoot it first.
mation q If failure codes [CB2265] or [CB2266] display, the pump system may be defective. Troubleshoot them
first.
NOTICE
This failure code requires the "Loaded Diagnostics Operation To Remove the Failure Code". After
you investigate the problem cause and complete the repair, perform "Loaded Diagnostics Operation
To Clear Failure Code" and make sure the failure code is removed. (This failure code is not removed

connector
2 Clogged fuel filter Check the fuel filter for clogging.
Clogged fuel filter or fuel
4 leakage from the connec- Check the fuel supply pipe and its joint bolt (JB).
tor.
Defective air intake mani- Remove the fuel pipe and examine for a blockage in the fuel connector on the fuel SHUT-
5
fold OFF manifold.

sure sensor
q Replace fuel doser solenoid valve 2-B (4B).
7 q If this failure code is not removed, the original fuel doser solenoid valve 2-A is defec-
noid valve 2-B
tive.
40-662 HD465-8, HD605-8


2. Start the engine and run it at low idle speed for 1 minute.
3. Perform "Active Regeneration for Service". For details, see TEST AND ADJUST, "SERVICE MODE" and "PROCEDURE
TO OPERATE REGENERATION FOR SERVICE TEST MENU" under "SET AND OPERATE OF MACHINE MONITOR".
NOTICE
If the failure code is removed when the Active Regeneration for Service completes, repair is completed.

1A. Fuel doser-A
1B. Fuel doser-B
a: From fuel pump-A
b: From fuel pump-B
c: Fuel return
nector
HD465-8, HD605-8 40-663

40-664 HD465-8, HD605-8


Action level Failure code KDPF Outlet Pressure Sensor High Error_2
Failure
Details of fail-
High voltage is generated in the signal circuit of KDPF outlet pressure sensor.
ure
Effect on the
machine
q If failure codes [CB1695] or [CB1696] are shown, the sensor power supply may be defective. Trouble-
shoot them first.

connector

Defective KDPF outlet
2
pressure sensor If this failure code changes to [CB3134], KDPF outlet pressure sensor is defective.
REMARK

Open circuit in wiring har- 2. Disconnect connectors ECM2 J2 and DPFP_2, and connect T-adapter to each female
3 side.
ness
Resistance Between ECM2 J2 (female) (32) and DPFP_2 (female) (1) Max. 1 Ω

Hot short circuit in wiring 3. Disconnect connector DPFP_2, and connect T-adapter to female side, or insert
4 T-adapter into connector ECM2 J2.
harness
Between DPFP_2 (female) (3) and (1), or between ECM2
Voltage Max. 1 V
J2 (42) and (32)

5
ness
pin (42)
HD465-8, HD605-8 40-665


40-666 HD465-8, HD605-8


Action level Failure code KDPF Outlet Pressure Sensor Low Error_2
Failure
Details of fail-
Low voltage is generated in the signal circuit of KDPF outlet pressure sensor.
ure
Effect on the
machine
q If failure codes [CB1695] or [CB1696] are shown, the sensor power supply may be defective. Trouble-
shoot them first.

connector

side.
2 Between ECM2 J2 (female) (32) and DPFP_2 (female) (1) Max. 1 Ω
ness
Resistance Between ECM2 J2 (female) (8) and DPFP_2 (female) (4) Max. 1 Ω
Between ECM2 J2 (female) (42) and DPFP_2 (female) (3) Max. 1 Ω

3
ness
Between ground and ECM2 J2 (female) (42) or DPFP_2
(female) (3)

4
ness No continuity
Continuity (no sound is
pin (42)
heard)

Defective KDPF outlet 2. Insert T-adapter into the connector DPFP_2.
pressure sensor
Voltage Between DPFP_2 (3) and (1) 0.5 to 4.5 V
HD465-8, HD605-8 40-667

1. Start the engine and run it at low idle for approximately 1 minute.
40-668 HD465-8, HD605-8


Action level Failure code KDPF Outlet Pressure Sensor In Range Error_2
Failure
Details of fail- Pressure sensed by the KDPF outlet pressure sensor indicates higher value than that in normal condition.
ure (Signal voltage is in operation range.)
q Operates the KDPF outlet pressure value at 0 kPa (gauge pressure).
q Closes EGR valve.
Action of con-
q Derates the engine power.
troller
Effect to the
machine
q If failure code [CB1695] or [CB1696] display, the sensor power supply could be defective. Troubleshoot
them first.
Related infor- OFF. Then turn the start switch to the ON position.
mation
NOTICE
q After you investigate the problem cause, and complete the repairs. Perform Loaded Diagnostics
Operation To Confirm Failure Correction to make sure the failure code is cleared.

connector
1. Remove the KDPF differential pressure sensor pipe.

2. Clean and remove blockage of the KDPF differential pressure sensor pipe.
3. Examine the KDPF differential pressure sensor pipe for cracks and damage.
Defective KDPF differen- 4. Install the KDPF differential pressure sensor pipe with the two connected tightly.
2
tial pressure sensor pipe 5. Perform Loaded Diagnostics Operation To Confirm Failure Correction.
REMARK
When failure code [CB1923] is shown, an open circuit in the GND line may occur.
HD465-8, HD605-8 40-669


2. Disconnect the connector PDPF_2.
REMARK
Ignore failure codes other than this failure code.

Defective wiring harness or 2. Disconnect connector DPFT2, and connect the short socket adapter to female side.
3 Connect 5 V to the signal line. (Short-circuit pins (4) and (3) of connector DPFP2.)
engine controller
REMARK
REMARK
Ignore failure codes other than this failure code.
Defective KDPF outlet If failure codes [CB3134] and [CB3133] are shown with these procedures, the KDPF out-
4
pressure sensor let pressure sensor is defective.

REMARK
If this failure code is shown during Loaded Diagnostics Operation To Confirm Failure Correction, go back to the troubleshoot
procedures.
2. Remove this failure code, Engine Controller_2, in the Engine Controller Active Fault from the service mode of the machine
monitor.
100% open position.
40-670 HD465-8, HD605-8

NOTICE
REMARK
30100)
7. If the oil temperature rises, switch the operation to low idle or high idle to lower it.
8. Repeat steps 6 and 7 continuously for approximately 50 minutes, make sure the torque converter does not become too hot.
REMARK
q If this failure code is not shown, the repair is completed.
q If this failure code is shown, go back to the troubleshoot procedures.
HD465-8, HD605-8 40-671


Action level Failure code Fuel Doser Degradation_2
Failure
Details of fail- q Fuel doser is deteriorated.

ure q The injection port of fuel doser is clogged.
Action of con-
None in particular
troller
Effect to the It takes time to perform automatic regeneration. (KDOC outlet temperature does not rise easily and it takes
machine too much time to burn the soot.)
q If failure codes [CB1927] or [CB1928] display, the fuel doser pressure sensor system may be defective.
Troubleshoot them first.
Troubleshoot them also.
q If failure code [CB1977] display, the fuel doser system may be defective. Troubleshoot it first.
q If failure codes [CB1963], [CB2878], or [CB2881] display, the fuel doser solenoid valve may be defec-
tive. Troubleshoot them first.
q Since this failure code has no action level, it is not displayed on the user screen of the machine monitor.
Related infor- This is displayed on the Service Menu and KOMTRAX terminal of the machine monitor.
mation NOTICE
q If this failure code is shown, the injection quantity of fuel doser is corrected. After the repair is
completed, make sure to perform Fuel Doser Memory Reset to reset the information of the cor-
rected doser injection amount. If you do not set the fuel doser information correctly, KCSF dam-
age will result.
q To complete the repair for this failure code, set the "fuel doser information" after you investigate
the cause and repaired the problem. When the fuel doser injector is replaced, complete the re-
pair, set the "fuel doser information". This failure code is not removed when you only set the "fu-
el doser information", it is removed after the next automatic regeneration completes.

connector

2. Remove the fuel doser (1B) from the exhaust connector.
The injection port of fuel 3. Clean the fuel doser
2
doser is clogged.
REMARK
To clean the fuel doser, see RELATED INFORMATION TO TROUBLESHOOT.
40-672 HD465-8, HD605-8


2. Remove the fuel doser-B (1B) from the exhaust connector.
3. Install the replacement fuel doser B (1B) in the exhaust connector.
REMARK
Install the doser correctly to prevent exhaust gas leakage.
3 Defective Fuel doser 4. Turn the start switch to the ON position.
5. Disable Regeneration
7. Run it at low idle for 2 minutes.
If there is no oil leakage from the point of the fuel doser-B (1B), the initial fuel doser-B (1B)
is defective.
1. Perform Fuel Doser Memory Reset.

Defective Fuel doser sys- 2. If this failure code shows again after you perform these procedures, the fuel doser
4
tem body has a blockage. Replace the doser fuel body. After the replacement, set the Fuel
Doser Information. (See below.)
How to Perform Fuel Doser Memory Reset.

1. Turn the starting switch to ON position. (Engine stops.)
2. From Service Menu of the machine monitor, open KDPF Memory Reset and perform KDPF Cleaning_2.
q If this failure code is shown, the injection quantity of fuel doser is corrected. After the repair is completed, make sure to
set the Fuel Doser Memory to set the information of the corrected doser injection quantity.
q If you do not set the fuel doser information correctly, KCSF damage will result.

1A. Fuel doser-A
1B. Fuel doser-B
a: From fuel pump-A
b: From fuel pump-B
c: Fuel return
tor
HD465-8, HD605-8 40-673


Action level Failure code KDOC Inlet Temperature High Error_2
Failure
Details of fail-
KDOC inlet temperature remains high.
ure
troller q Derates the engine power.
Effect to the
machine
q If failure codes [CB3313], [CB3314], or [CB3315] are shown, KDOC inlet temperature sensor may be
defective. Troubleshoot them first.
q If failure codes [CB1925] or [CB1963] are shown, the fuel doser solenoid valve 1 may be defective. Trou-
bleshoot them first.
q When a cylinder misfire occurs:
1. A cylinder misfire impairs combustion and causes higher exhaust temperature.
2. The other cylinders compensate for the torque drop because of a defective cylinder and increase
fuel injection. This may cause higher exhaust temperature.
q Engine power derate is stopped when you turn the start switch to the OFF position after this failure code
is removed. (This derate is not removed when you remove the failure code.)
NOTICE
Related infor-
mation If this failure code is shown, KCSF damage may occur. Examine these after you repair the failure
code. Replace the KCSF if the black smoke comes out of the exhaust pipe outlet (tale pipe outlet).
q Make sure that black smoke does not come out of the exhaust pipe outlet during acceleration and at
high idle.
NOTICE

connector
Examine air intake hoses, clamps, and pipes for damage or loose connection, and repair
as necessary.

2. Check for oil or fuel stuck to the inner side of the turbocharger exhaust connector.
Oil leakage into the turbo- NOTICE
4
leakage. Repair as necessary if a defect is found.
q Completely clean the oil or fuel stuck to the piping.
40-674 HD465-8, HD605-8


Oil leaks into the exhaust Examine the exhaust system between the turbocharger and KDPF for of oil or fuel.
5 connector or pipe to the q If oil or fuel is stuck, clean it completely.
KDPF q If signs of oil or fuel are found in the KDPF, clean it or replace it as required.
sensor necessary.
Defective KDPF tempera- If the failure code is not removed with these procedures, replace the KDPF temperature
7
ture sensor sensor.

NOTICE
If this failure code is cleared, the repair is completed.
HD465-8, HD605-8 40-675


Action level Failure code KDOC Temperature Error - Non Regeneration_2
Failure
Details of fail-
KDOC outlet temperature remains at high level when Active Regeneration is not performed.
ure
q Closes EGR valve.
Action of con- q Derates the engine power.
troller q Stops the fuel dosing.
Effect to the
machine
q If failure codes [CB3313], [CB3314], or [CB3315] display, KDOC inlet temperature sensor may be de-
fective. Troubleshoot them.
q If failure codes [CB3316], [CB3317], or [CB3318] are shown, KDOC outlet temperature sensor may be
defective. Troubleshoot them.

high idle.
NOTICE

connector
as necessary.
40-676 HD465-8, HD605-8


4
1. Remove KDPF.
2. Remove KDPF.
the inner side.
Defective KDOC (stain, 6. Perform KDPF Memory Reset after installation or replacement of KDOC or KDPF. For
6
crack, damage) details, see TEST AND ADJUST, "SERVICE MODE" and "PROCEDURE TO
REMARK
7
KDOC catalyzer function) does not appear, set the KDPF Memory and then complete the troubleshoot proce-
dures.
REMARK
sensor necessary.
sensor necessary.
10
ture sensor sensor.
HD465-8, HD605-8 40-677



If the failure code is removed, the repair is completed. If the failure code is not removed, perform these steps.
NOTICE
If the failure code does not clear after steps 1 and 2, perform these temperature requirements are necessary to
remove the codes. Steps 5 and 6 are the operations to satisfy the temperature requirements.
q KDOC inlet temperature is 200 °C or higher.
3. Display KDOC inlet and KDOC outlet temperatures with the monitor function.
REMARK
NOTICE
Engine speed does not increase to approximately 2270 rpm high idle without the parking brake released.
6. If KDOC inlet or KDOC outlet temperatures does not exceed 200 °C or higher. Perform the Loaded Diagnostics Operation
To Remove Failure Code for failure code [CB1883].
REMARK
q If this failure code is not removed, go back to the troubleshoot procedures.
40-678 HD465-8, HD605-8


Action level Failure code KDOC Outlet Temperature High Error 1_2
Failure
Details of fail-
KDOC outlet temperature remains at high level.
ure
Action of con-
None in particular
troller
Effect to the
None in particular
machine
NOTICE
If this failure code is shown, KCSF damage may occur. Examine these after you repair the failure
Related infor- code. Replace the KCSF if the black smoke comes out of the exhaust pipe outlet (tale pipe outlet).
mation
q Start the engine, accelerate the engine from low idle to high idle twice, and then hold the engine at high
idle for 5 seconds.
high idle.
NOTICE

as necessary.

3
HD465-8, HD605-8 40-679

1. Remove KDPF.
2. Remove KDPF.
the inner side.
Defective KDOC (stain, 6. Perform KDPF Memory Reset after installation or replacement of KDOC or KDPF. For
5
crack, damage) details, see TEST AND ADJUST, "SERVICE MODE" and "PROCEDURE TO
REMARK
KDOC catalyzer function)
does not appear, set the KDPF Memory and then complete the troubleshoot procedures.
REMARK
sensor necessary.
8
ture sensor sensor.

1. Turn the start switch from the OFF position to the ON position.
2. Start the engine and run at low idle for 1 minute.
3. Perform Active Regeneration for Service.
NOTICE
q Perform Active Regeneration for Servicer for 15 minutes.
q If the failure code is removed when the Active Regeneration for Service completes, repair is completed.
40-680 HD465-8, HD605-8


Action level Failure code KDPF Temperature Error - Non Regeneration_2
Failure
Details of fail-
KDPF outlet temperature remains at high level when Active Regeneration is not performed.
ure
q Closes EGR valve.
Action of con- q Derates engine power.
Effect to the
machine
q If failure codes [CB3319], [CB3321], or [CB3322] show, KDPF outlet temperature sensor may be defec-
tive. Troubleshoot them.
NOTICE
Related infor-
idle for 5 seconds.
mation
high idle.
NOTICE
Clear Failure Code to make sure the failure code is cleared. (This failure code is not cleared by
only turning the starting switch to ON position.)

as necessary.

3
sensor necessary.
6
ture sensor sensor.
HD465-8, HD605-8 40-681



2. If the failure code is removed after running the engine at low idle speed for approximately 15 minutes, the repair is
completed. If the failure code is not removed, perform the steps that follow.
NOTICE
If the failure code does not clear after steps 1 and 2, perform these temperature requirements are necessary to
remove the codes. Steps 5 and 6 are the operations to satisfy the temperature requirements.
q KDPF outlet temperature is 200 °C or higher.
3. Display KDOC outlet temperature and KDOC outlet temperature with the monitor function.
REMARK
q Temperature detected by KDPF outlet temperature sensor can be checked by the monitoring function. (Code: 47402)
NOTICE
Engine speed does not increase to approximately 2270 rpm high idle without the parking brake released.
6. If KDOC outlet temperature or KDPF outlet temperature does not exceed 200 °C or higher, perform Loaded Diagnostics
Operation To Clear Failure Code for [CA1883].
REMARK
q If this failure code is not removed, go back to the troubleshoot procedures.
40-682 HD465-8, HD605-8


Action level Failure code KDPF Outlet Temperature High Error 1_2
Failure
Details of fail-
ure
Action of con-
None in particular
troller
Effect to the
None in particular
machine
q If failure codes [CB3319], [CB3321], or [CB3322] are shown, KDPF outlet temperature sensor may be
OFF. Then turn the start switch to the ON position.
NOTICE
Related infor- If this failure code is shown, KCSF damage may occur. Examine these after you repair the failure
mation code. Replace the KCSF if the black smoke comes out of the exhaust pipe outlet (tale pipe outlet).
idle for 5 seconds.
high idle.
NOTICE

as necessary.

3
sensor necessary.
HD465-8, HD605-8 40-683


6
ture sensor sensor.

4. From Service menu of the machine monitor, display Diagnostic Tests screen, open Active Regeneration for Service, and
then perform Manual Stationary Regeneration.
NOTICE
q Perform Active Regeneration for Servicer for at least 15 minutes.
q If the failure code is removed when the Active Regeneration for Service completes, repair is completed.
40-684 HD465-8, HD605-8


Action level Failure code KDOC Outlet Temperature High Error 2_2
Failure
Details of fail-
KDOC outlet temperature remains at a high level compared to the KDOC inlet temperature.
ure
q Closes EGR valve.
Effect to the
machine
NOTICE
Related infor-
mation
idle for 5 seconds.
high idle.
NOTICE
q After you investigate the problem cause, and complete the repair. Perform the Loaded Diagnos-
tics Operation To Confirm Failure Correction to make sure this failure code is removed. (Al-
though this failure code does not show with the start switch turned ON, High exhaust
temperature is required to make sure the repair is completed.)

as necessary.

3
sensor necessary.
HD465-8, HD605-8 40-685


6
ture sensor sensor.

1. Turn the start switch from OFF to the ON position.
NOTICE
The failure code is cleared once when the start switch is turned from the OFF position to the ON position. Make
sure that the removed failure code is not shown again while the engine runs at low idle speed.
2. Start the engine and run it at low idle speed for 2 minutes.
NOTICE
If this failure code shows when the start switch is turned on, and the engine does not start troubleshoot and repair
this failure code initially. Then also troubleshoot for these other failure codes.
q [CB3316] KDOC Outlet Temperature Sensor Low Error_2
q [CB3317] KDOC Outlet Temperature Sensor High Error_2
40-686 HD465-8, HD605-8


Action level Failure code KDPF Outlet Temperature High Error 2_2
Failure
Details of fail-
ure
Action of con-
None in particular
troller
Effect on the
None in particular
machine
q If failure codes [CB3319], [CB3321], or [CB3322] display, KDPF outlet temperature sensor may be de-
fective. Troubleshoot them.
NOTICE
Related infor-
high idle.
NOTICE
q This failure code requires Loaded Diagnostics Operation To Confirm Failure Correction. After
you investigate the problem cause, and complete the repair. Perform the Loaded Diagnostics
Operation To Confirm Failure Correction and make sure the failure code is removed.

as necessary.

3
sensor necessary.
HD465-8, HD605-8 40-687


6
ture sensor sensor.

1. Turn the start switch from OFF to the ON position.
NOTICE
The failure code is cleared once when the start switch is turned from the OFF position to the ON position. Make
sure that the removed failure code is not shown again while the engine runs at low idle speed.
2. Start the engine and run it at low idle speed for 2 minutes.
NOTICE
If this failure code shows when the start switch is turned on, and the engine does not start troubleshoot and repair
this failure code initially. Then also troubleshoot for these other failure codes.
q [CB3319] KDPF Outlet Temperature Sensor High Error_2
q [CB3321] KDPF Outlet Temperature Sensor Low Error_2
40-688 HD465-8, HD605-8


Action level Failure code KDOC Inlet Temperature Sensor Low Error_2
Failure
Details of fail- Ground fault or unusual sensor circuit in the measured section or probe (+) side of the KDOC outlet temper-
ure ature sensor
q Replaces the KDOC outlet temperature for the KDOC inlet temperature to run the engine. (If the KDOC
outlet temperature sensor is also defective, uses KDOC inlet temperature at a set value (250 °C) and
runs the engine.)
Action of con-
q Derates engine power.
troller
q Closes EGR valve.
Effect on the
machine
Related infor- q Engine power derate is stopped when you turn the start switch to the OFF position after this failure code
mation is removed. (This derate is not removed when you remove the failure code.)

connector

REMARK
perature sensor
BLY".
HD465-8, HD605-8 40-689


Action level Failure code KDOC Inlet Temperature Sensor High Error_2
Failure
Details of fail- Open circuit, hot short circuit, or abnormal sensor circuit in the measured section or probe (+) side of the
ure KDOC inlet temperature sensor
runs the engine.)
Action of con-
troller
q Closes EGR valve.
Effect on the
machine

connector

REMARK
perature sensor
BLY".
40-690 HD465-8, HD605-8


Action level Failure code KDOC Inlet Temperature Sensor In Range Error_2
Failure
The difference between the temperature sensed by KDOC inlet temperature sensor and the temperature
Details of fail-
sensed by KDOC outlet temperature sensor differs from the expected value. (Signal voltage is in input
ure
range.)
runs the engine.)
Action of con-
q Closes EGR valve.
troller
Effect on the
machine
q If the failure code [CB3313] and [CB3314] are displayed, KDOC inlet temperature sensor may be de-
fective. Perform troubleshooting for [CB3313] and [CB3314].
Related infor- q To start the engine, after you have turned the start switch OFF, wait until the system operation light is
mation OFF. Then turn the start switch to the ON position.
NOTICE

connector
REMARK
Defective KDOC inlet tem- q Temperature detected by KDOC outlet temperature sensor can be checked by the
perature sensor
ASSEMBLY".
as necessary.
HD465-8, HD605-8 40-691



5
Examine the exhaust system between the turbocharger and KDPF for of oil or fuel.
Oil leakage into exhaust
6 q If oil or fuel is stuck, clean it completely.
connector or duct to KDPF
q If signs of oil or fuel are found in the KDPF, clean it or replace it as required.
sensor necessary.
8
ture sensor sensor.

REMARK
procedures.
monitor.
100% open position.
NOTICE
REMARK
30100)
40-692 HD465-8, HD605-8

REMARK
HD465-8, HD605-8 40-693


Action level Failure code KDOC Outlet Temperature Sensor Low Error_2
Failure
Details of fail- Ground fault or unusual sensor circuit in the measured section or probe (+) side of the KDOC outlet temper-
ure ature sensor
q Replaces the KDOC inlet temperature for the KDOC outlet temperature to run the engine, because
Action of con-
troller
q Closes EGR valve.
Effect on the
machine

connector
1. Check the sensor connector for any tension or damage

REMARK
temperature sensor
BLY".
40-694 HD465-8, HD605-8


Action level Failure code KDOC Outlet Temperature Sensor High Error_2
Failure
Details of fail- Open circuit, hot short circuit, or abnormal sensor circuit in the measured section or probe (+) side of the
ure KDOC outlet temperature sensor
q Replaces the KDOC inlet temperature for the KDOC outlet temperature to run the engine, because
Action of con-
troller
q Closes EGR valve.
Effect on the
machine

connector

REMARK
temperature sensor
BLY".
HD465-8, HD605-8 40-695


Action level Failure code KDOC Outlet Temperature Sensor In Range Error_2
Failure
The difference between the temperature detected by KDOC outlet temperature sensor and the temperature
Details of fail-
detected by KDOC inlet temperature sensor differs from the expected value. (Signal voltage is within input
ure
range.)
q Replaces the KDOC inlet temperature for the KDOC outlet temperature to run the engine. (If the KDOC
inlet temperature sensor is also defective, the controller uses the KDOC outlet temperature at a set val-
ue (250 °C) and runs the engine.)
Action of con-
q Closes EGR valve.
troller
Effect on the
machine
q If failure codes [CB3316] and [CB3317] are shown, KDOC outlet temperature sensor may be defective.
Troubleshoot them.
(Code: 47302)
(Code: 47402)
OFF. Then turn the start switch to the ON position.
NOTICE

connector

REMARK
temperature sensor
BLY".
40-696 HD465-8, HD605-8


as necessary.

5
sensor necessary.

Defective KDPF tempera- 2. If the failure code is not removed with these procedures, replace the KDPF tempera-
8

REMARK
procedures.
monitor.
100% open position.
HD465-8, HD605-8 40-697

NOTICE
REMARK
30100)
REMARK
40-698 HD465-8, HD605-8


Action level Failure code KDPF Outlet Temperature Sensor High Error_2
Failure
Details of fail- Open circuit, hot short circuit, or unusual sensor circuit in the measured section or probe (+) side of the
ure KDPF outlet temperature sensor
Action of con-
troller
q Closes EGR valve.
Effect to the q Defective active regeneration control
machine q Soot accumulation is high.

connector

REMARK
perature sensor
BLY".
HD465-8, HD605-8 40-699


Action level Failure code KDPF Outlet Temperature Sensor Low Error_2
Failure
Details of fail-
Ground fault in KDPF outlet temperature sensor measuring section or probe (+) side
ure
Action of con-
troller
q Closes EGR valve.
Effect to the q Defective active regeneration control
machine q Soot accumulation is high.

connector

REMARK
perature sensor
BLY".
40-700 HD465-8, HD605-8


Action level Failure code KDPF Outlet Temperature Sensor In Range Error_2
Failure
Details of fail- The temperature sensed by the KDPF outlet temperature sensor differs from the expected value. (Signal
ure voltage is in input range.)
Action of con-
troller
q Closes EGR valve.
Effect on the
machine
q If failure codes [CB3319] and [CB3321] are shown, KDPF outlet temperature sensor may be defective.
Troubleshoot them.
q Temperature detected by KDPF outlet temperature sensor can be checked by monitoring function.
(Code: 47202)
NOTICE

connector

REMARK
perature sensor
BLY".
as necessary.
HD465-8, HD605-8 40-701


5
sensor necessary.

Defective KDPF tempera- 2. If the failure code is not removed with these procedures, replace the KDPF tempera-
8

REMARK
procedures.
monitor.
6. Set the Power Mode to "P".
100% open position.
NOTICE
REMARK
30100)
40-702 HD465-8, HD605-8

REMARK
HD465-8, HD605-8 40-703


Action level Failure code KDOC and KDPF Temperature Sensor Datalink Timeout Error_2
Failure
q Engine controller does not receive data from the KDOC inlet, outlet, and KDPF outlet temperature sen-
Details of fail- sors. There is a communication Fault with the KDPF temperature sensor.
ure q This occurs when the information from the KDOC inlet, KDOC outlet, and KDPF outlet temperature sen-
sors are not received in a certain quantity of time.
gine at a specified value (250 °C).
troller q Closes EGR valve.
Effect on the
machine
q KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature detection is disabled.
k Exhaust connector for the turbocharger, pipes for the installed sensors, KDPF, and KDOC, be-
come very hot (Minimum 500 °C). Be careful not to become burned.

connector

2. Check if circuit breaker FuB2 is tripped.
2 Defective circuit breaker q If the circuit breaker is open, troubleshoot for a ground fault in the wiring harness.
q If wiring harness has no ground fault, and if circuit breaker does not reset normally,
circuit breaker is defective.

3 Defective fuse 3. If the fuse is not blown out, perform a continuity test to check if it is broken.

2. Disconnect connector DPFT2, and connect T-adapter to female side.
4
ness (power supply circuit) Between DPFT2 (female) (4) and battery relay terminal 77 Max. 1 Ω
Resistance

2. Disconnect connectors DLK2, and CEN22_RES, and connect T-adapter to each male
side.
Defective CAN terminating
5 Approx. 120
resistor Between DLK2 (male) (A) and (B)
Ω
Resistance
Approx. 120
Between CEN22_RES (male) (A) and (B)
Ω
40-704 HD465-8, HD605-8


2. Disconnect connectors ECM2 J2, DPFT_2, DLK2, and CEN22-RES, and connect
Between ECM2 J2 (female) (21) and DPFT2 (female) (3) Max. 1 Ω
Between ECM2 J2 (female) (45) and DPFT2 (female) (2) Max. 1 Ω
6 ness (CAN communication
line) Between DLK2 (female) (A) and DPFT2 (female) (3) Max. 1 Ω
Resistance
Between DLK2 (female) (B) and DPFT2 (female) (2) Max. 1 Ω
Between CEN22-RES (female) (A) and DPFT2 (female) (3) Max. 1 Ω
Between CEN22-RES (female) (B) and DPFT2 (female) (2) Max. 1 Ω

2. Disconnect connectors ECM1 J2, DPFP_2, DLK2, and CEN22-RES, and connect
Open circuit in wiring har- Between ground and either ECM2 J2 (female) (21), DLK2
7 ness (CAN communication (female) (A), CEN22_RES (female) (A), or DPFT2 (female) Min. 1 MΩ
line) (3)
Resistance
Between ground and either ECM2 J2 (female) (45), DLK2
(female) (B), CEN22_RES (female) (B), or DPFT2 (female) Min. 1 MΩ
(2)

2. Disconnect the connector CEN22_RES, and insert into T-adapter.
8 harness (CAN communica-
tion line) Between CEN22_RES (A) and ground 1 to 4 V
Voltage
Between CEN22_RES (B) and ground 1 to 4 V

9
HD465-8, HD605-8 40-705

Circuit diagram related to CAN system
40-706 HD465-8, HD605-8


Action level Failure code KDOC/KDPF Temp Sensor Internal Circuit Error_2
Failure
Details of fail- Error is sensed in one of the sensor circuit of the KDOC inlet temperature sensor, KDOC outlet temperature
ure sensor, or KDPF outlet temperature sensor.
gine at a specified value (250 °C).
Effect on the
machine
q Either KDOC inlet, KDOC outlet, or the KDPF outlet temperatures are not sensed.

connector

2
HD465-8, HD605-8 40-707


Action level Failure code KDOC and KDPF Temperature Sensor ECU Voltage High Error_2
Failure
Details of fail-
High voltage error is detected in power supply of KDPF temperature sensor controller.
ure
q Uses the KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature to run the
engine at a set value (250 °C).
Effect on the
machine
q The KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature are not sensed.

connector
Battery voltage (1 battery) Min. 12 V
2 Defective battery
Battery voltage (2 Batteries) Min. 24 V

Defective input voltage of 2. Disconnect connector DPFT2, and connect T-adapter to female side.

4
40-708 HD465-8, HD605-8

Circuit diagram related to KDOC/KDPF temperature sensor
HD465-8, HD605-8 40-709


Action level Failure code KDOC and KDPF Temperature Sensor ECU Voltage Low Error_2
Failure
Details of fail-
Low voltage error is detected in power supply of KDPF temperature sensor controller.
ure
q Uses the KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature to run the
engine at a set value (250 °C).
Effect on the
machine
q The KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature are not sensed.
Related infor-
mation Engine power derate is stopped when you turn the start switch to the OFF position after this failure code is
removed. (This derate is not removed when you remove the failure code.)

connector
2 Defective battery

Defective input voltage of 2. Disconnect connector DPFT2, and connect T-adapter to female side.

4
40-710 HD465-8, HD605-8

HD465-8, HD605-8 40-711


Action level Failure code KDOC and KDPF Temperature Sensor ECU Over Temperature Error_2
Failure
Details of fail-
KDOC and KDPF Temperature Sensor ECU Over Temperature Error
ure
Action of con-
None in particular
troller
Effect on the q Defective active regeneration control
machine q The KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature are not sensed.
To start the engine, after you have turned the start switch OFF, wait until the system operation light is OFF.
Then turn the start switch to the ON position.
mation After you investigate the problem cause, and complete the repair. Perform the Loaded Diagnostics
Operation To Confirm Failure Correction to make sure this failure code is removed.
(When this failure code does not show with the start switch turned to ON position. High exhaust tem-
peratures are required to make sure that the repair is completed.)

Make sure the temperature around the controller is not abnormally high (150 °C or
1 Exhaust gas leakage
higher).

Defective KDPF tempera- 3. Turn the start switch to the ON position.
2
ture sensor

REMARK
procedures.
2. Turn the start switch to the ON position, and make sure the failure code is removed. If this failure code is shown, go back
to the troubleshoot procedures.
4. Run the engine at low idle speed for 10 minutes.
5. Run the engine at high idle speed for 10 minutes.
6. If this failure code is removed, repair is complete.
40-712 HD465-8, HD605-8

HD465-8, HD605-8 40-713


Action level Failure code KDOC and KDPF Temperature Sensor Power Interrupt Error_2
Failure
Details of fail- KDPF temperature sensor interrupt power failure error (12 open circuits are detected in the power supply
ure line in 60 seconds.)
q Set value of the KDOC inlet temperature, KDOC outlet temperature, and the KDPF outlet temperature
(250 °C)
q KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature detection error.
Effect on the
q Defective regeneration control.
machine
q Soot accumulation is high and engine power decreases.
q Examine a torn harness cover visually for contact failure at the connector because the momentary pow-
er failure is usually caused by contact failure.
q To detect a not completed wire break, move the wiring harness as much as possible during this test to
Related infor- determine if there is a change or not.
mation q Note that the sensor power supply relay is energized, although the start switch is in the OFF position.
Procedure: start the engine and operate the machine. (Apply vibration to the machine.)

connector

2. Disconnect connector DPFT2, and connect T-adapter to female side.
2
ness (power supply circuit) Between DPFT2 (female) (4) and battery relay terminal 77 Max. 1 Ω
Resistance

Defective KDPF tempera- 3. Turn the start switch to the ON position.
3
ture sensor
40-714 HD465-8, HD605-8

Circuit diagram related to KDPF temperature sensor
HD465-8, HD605-8 40-715


Action level Failure code Operating Lamp Short Circuit (ENG Con)_2
Failure
Details of fail- Engine controller senses a system operation lamp short circuit. The voltage on the output circuit goes to a
ure low level compared to the engine controller output system voltage.
Action of con-
Stops the system operation lamp.
troller
Effect on the
None in particular
machine
Related infor- After the repair is completed, make sure the failure code is removed with these procedures.

connector

2. While this failure code is shown, the system operation lamp is turned off and is not
visible. Turn the battery disconnect switch to the OFF position, 3 minutes after you turn
Hot short circuit in wiring the start switch OFF
2

the start switch OFF
3 4. Disconnect connectors ATC3, KOM1A, MCM1, ECM1 J2, ECM2 J2, BRC3, OPC3,
ness
KPS2, OPL, and CAB2 and connect T-adapter to female side of OPL.
REMARK
Connector OPC3 is only for the machine with ABS system.
Resistance Between OPL (female) (1) and (2) Min. 1 MΩ
40-716 HD465-8, HD605-8

HD465-8, HD605-8 40-717

40-718 HD465-8, HD605-8


Action level Failure code Ash Accumulation High Error_2
Failure
Details of fail-
There is much ash accumulation in KDPF. It is necessary to clean the ash.
ure
Action of con-
None in particular
troller
Phenomenon
KCSF may be damaged.
on machine
q If the failure codes [CB1879], [CB1881], or [CB1883] display, the KDPF differential pressure sensor may
be defective. Troubleshoot these first.
q If active regeneration is executed frequently, troubleshoot for Active Regeneration Takes Time in S
mode.
q When ash accumulation increases to the upper limit, this failure code is shown.
Related infor- q This failure code is not displayed on the machine monitor, but is displayed on Abnormality Record
mation screen in service mode on the machine monitor and KOMTRAX terminal.
NOTICE
q When this failure code is shown troubleshoot for a defective KDPF differential pressure sensor
and defective KDPF (KDOC, KCSF). Then make sure you perform an ash clean out procedure.
q After the ash is cleaned out, set the KDPF Clean and KDPF Change.
q If you do not set the fuel doser information correctly, KCSF damage will result.
NOTICE
Make sure you perform these procedures.
1. Remove the KDPF to flush out the ash accumulated in it. When the ash accumulation
increase to its upper limit, KDPF experiences a very high-pressure drop and requires
clean out.
Excessive ash accumula-
1 3. Set the KDPF Clean or Replace.
tion
To reset KDPF cleaning and KDPF replacing, see TEST AND ADJUST, "SERVICE
MODE" and "PROCEDURE TO OPERATE THE TEST MENU (KDPF MEMORY
RESET)" under "SET AND OPERATE OF MACHINE MONITOR".
4. Check that the ash accumulation level is 0 on the monitor screen. For details, see
TEST AND ADJUST, "SERVICE MODE" and "PROCEDURE TO OPERATE ASH IN
SOOT ACCUMULATION CORRECTION TEST MENU" under "SET AND OPERATE
HD465-8, HD605-8 40-719

FAILURE CODE [D150KB] 40 TROUBLESHOOTING
FAILURE CODE [D150KB]

Action level Failure code Secondary Steering Motor Relay Output Ground Fault
Failure
L03 D150KB (Retarder and hoist controller system)
Details of fail- When the controller operates the primary circuit (coil) of the automatic secondary steering relay, there is a
ure large current flow.
q Stops driving the automatic secondary steering relay.
Action of con-
q Although the failure cause is eliminated, the machine does not go back to normal until the start switch is
troller
turned to the OFF position.
Effect on the
Automatic secondary steering does not work.
machine
q When the start switch is turned to the ON position, the controller operates the secondary steering relay to
Related infor- diagnose the secondary steering motor.
mation q After the repair is completed, make sure the failure code is removed with these procedures.

2. Disconnect connector R17, and connect T-adapter to male side.
Defective automatic sec-
1
ondary steering relay Between R17 (male) (1) and (2) 290±30 Ω
Resistance
Between R17 (male) (1) and ground Min. 1 MΩ

Ground fault in wiring har- 2. Disconnect connectors BRC3 and R17, and connect T-adapter to either female side.
2
ness Between ground and BRC3 (female) (28) or R17 (female)
(1)

Short circuit in wiring har- 2. Disconnect connectors BRC3 and R17, and connect T-adapter to either female side.
3
ness Between BRC3 (female) (28) and (23), or between R17
Defective retarder and If no failure is found with these procedures, the retarder and hoist controller is defective.
4
Circuit diagram related to secondary steering motor relay
40-720 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [D150KZ]
FAILURE CODE [D150KZ]

Action level Failure code Secondary Steering Motor Relay Output Open Circuit or Hot Short Circuit
Failure
L03 D150KZ (Retarder and hoist controller system)
Details of fail- When the controller operates the primary circuit (coil) on automatic secondary steering relay no current flows.
ure When the controller does not operate relay, the current flows.
Action of con-
None in particular
troller
Effect on the
Automatic secondary steering does not work or will not stop.
machine
q When the start switch is turned to the ON position, the controller operates the secondary steering relay to
Related infor- diagnose the secondary steering motor.

Defective automatic sec- 2. Disconnect connector R17, and connect T-adapter to male side.
1
ondary steering relay

2. Disconnect connectors BRC3 and R17, and connect T-adapter to each female side.
2
ness Between BRC3 (female) (28) and R17 (female) (1) Max. 1 Ω
Resistance
Between BRC3 (female) (23) and R17 (female) (2) Max. 1 Ω

Hot short circuit in wiring 2. Disconnect connector R17, and connect T-adapter to female side.
harness
Voltage Between R17 (female) (1) and (2) Max. 4.5 V
4
Circuit diagram related to secondary steering motor relay
HD465-8, HD605-8 40-721

FAILURE CODE [D164KY] 40 TROUBLESHOOTING
FAILURE CODE [D164KY]

Action level Failure code Head Light High Select Relay Hot Short Circuit
Failure
L01 D164KY (Machine monitor system)
Details of fail- When the controller operates the headlamp (high beam) relay, the output terminal voltage of the monitor con-
ure troller is 5.7 V or higher.
q Stops operation of the headlamp (high beam) relay.
Action of con-
troller
Effect on the
Headlamp (high beam) does not light up. (However, passing lamp works normally.)
machine
q Command (ON/OFF) from the controller to headlamp (high beam) relay can be checked by monitor func-
Related infor- tion. (Code: 04700)
Procedure: Turn the start switch to the ON position and high beam operation

harness
Voltage Between R07 (female) (2) and ground Max. 1 V
Defective monitor control- If no failure is found with these procedures, the monitor controller is defective. (Since this
2
Circuit diagram related to headlamp relay
40-722 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [D19HKZ]
FAILURE CODE [D19HKZ]

Action level Failure code Stop Lamp Relay Output Open Circuit or Hot Short Circuit (Right & Left)
Failure
L01 D19HKZ (Retarder and hoist controller system)
q When the controller operates the primary circuit (coil) of the brake lamp operation relay, no current flows
Details of fail- or excessive current flows through the circuit.
ure q When the controller does not operate primary circuit (coil) of the brake lamp relay, the current flows
through the circuit.
Action of con-
If the cause of failure is a ground fault, the operation of the stop lamp output circuit stops.
troller
Effect on the
Stop lamp does not illuminate or it stays illuminated.
machine
mation Procedure: Turn the start switch to the ON position and depress the brake pedal.

Defective brake lamp oper- 2. Disconnect connector R03, and connect T adapter to the male side.
1
ation relay
Resistance Between the connectors R03 (male) (1) and (2) 290±30 Ω
1. When the controller does not operate primary circuit (coil) of the brake lamp relay, the
current flows through the circuit.
Open circuit in wiring har- 2. Disconnect connectors BRC3 and R03, and connect T-adapter to each female side.
2
ness
Resistance

3
(1)

4

harness
Voltage Between R03 (female) (1) and (2) Max. 4.5 V

2. Insert T-adapter into connector BRC3.
Between BRC3 (25) and Retarder and foot brake:
Defective retarder and Max. 1 V
6 (13) OFF
hoist controller Voltage
Between BRC3 (25) and
Retarder or foot brake: ON 20 to 30 V
(13)
If no failure is found with these procedures, the retarder and hoist controller is defective.
HD465-8, HD605-8 40-723

FAILURE CODE [D19HKZ] 40 TROUBLESHOOTING
Circuit diagram related to brake lamp relay
40-724 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [D19JKZ]
FAILURE CODE [D19JKZ]

Action level Failure code Personal Code Relay Output Open Circuit or Ground Fault
Failure
L03 D19JKZ (Machine monitor system)
Details of fail- When the controller does not operate the primary circuit (coil) of the personal code relay, the output voltage
ure decreases lower than 5.7 Volts.
Action of con-
None in particular
troller
Effect on the q When an open circuit occurs, the controller will not operate, although the engine start lock is activated.
machine q When a ground fault occurs, the controller system will not operate.
q Output condition (ON/OFF) from the controller to the personal code relay is examined with monitor func-
Related infor- tion. (Code: 04700)

If the fuse No.3 in the fuse box BT4 is blown out, the circuit probably has a failure such as
1 Defective fuse
a ground fault.

Defective personal code 2. Disconnect connector R02, and connect T-adapter to male side.
2
relay

2. Disconnect connectors MCM1 and R02, and connect T-adapter to each female side.
Open circuit in wiring har- 3. Remove the fuse No.3 in fuse box BT4.
3
ness
Between MCM1 (female) (19) and R02 (female) (2) Max. 1 Ω
Resistance
Between BT4-6 and R02 (female) (1) Max. 1 Ω

2. Disconnect connectors MCM1 and R02, and connect T-adapter to either female side.
4
ness Between ground and MCM1 (female) (19) or R02 (female)
Min. 1 MΩ
Resistance (2)
Between ground and BT4-6 or R02 (female) (1) Min. 1 MΩ
5
Circuit diagram related to personal code relay
HD465-8, HD605-8 40-725

FAILURE CODE [D19QKZ] 40 TROUBLESHOOTING
FAILURE CODE [D19QKZ]

Action level Failure code Stop Lamp (Center) Output System Abnormality
Failure
L01 D19QKZ (Retarder and hoist controller system)
q When the controller operates the primary circuit (coil) of the brake lamp operation relay, no current flows
Details of fail- or excessive current flows through the circuit.
ure q When the controller does not operate primary circuit (coil) of the brake lamp relay, the current flows
through the circuit.
Action of con-
If the cause of failure is a ground fault, the operation of the stop lamp output circuit stops.
troller
Effect on the
Stop lamp does not illuminate or it stays illuminated.
machine
mation Procedure: Turn the starting switch to ON position and depress the brake pedal.

Defective brake lamp oper- 2. Disconnect connector R05, and connect T-adapter to the male side.
1
ation relay
Resistance Between the connectors R03 (male) (1) and (2) 290±60 Ω

2. Disconnect connectors BRC3 and R05, and connect T-adapter to each female side.
2
ness Between BRC3 (female) (15) and R05 (1) Max. 1 Ω
Resistance
Between BRC3 (female) (13) and R05 (2) Max. 1 Ω

3
(1)

4
ness Between BRC3 (female) (15) and (13) or between R05 (1)
and (2)

2. Disconnect connector R05, and connect T-adapter to female side.
5
harness REMARK
Do not depress the brake pedal and secondary brake pedal.
Voltage Between R05 (female) (1) and (2), or between grounds Max. 4.5 V

Defective retarder and Foot brake: OFF Max. 4.5 V
6 (13)
Foot brake: ON 20 to 30 V
(13)
40-726 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [D19QKZ]
Circuit diagram related to battery relay
HD465-8, HD605-8 40-727

FAILURE CODE [D1EHKA] 40 TROUBLESHOOTING
FAILURE CODE [D1EHKA]

Action level Failure code Engine Start Relay Output Open Circuit
Failure
L03 D1EHKA (Transmission controller system)
Details of fail- When the controller operates the primary circuit (coil) of the engine start relay, no current flows through the
ure circuit.
Action of con-
None in particular
troller
Effect on the
Engine will not start.
machine
q The output signal to the engine start relay is examined with monitor function. (Code: 03706)
Related infor-
mation

1 Defective engine start relay 2. Disconnect connector R01, and connect T-adapter to male side.

2. Disconnect diode D16, and connect T-adapter to male side.
REMARK
2 Defective diode Measure it with diode range.
Between D16 (male) (2) (-) and (1) (+) No continuity
Continuity With continu-
Between D16 (male) (2) (+) and (1) (-)
ity

2. Disconnect connectors ATC3 and R01, and D16, and connect T-adapter to each
female side.
3 Between ATC3 (female) (25) and D16 (female) (2) Max. 1 Ω
ness
Resistance Between D16 (female) (1) and R01 (female) (1) Max. 1 Ω
Between R01 (female) (2) and ATC3 (female) (3) Max. 1 Ω
Defective transmission If no failure is found with the previous procedures, the transmission controller is defective.
4
40-728 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [D1EHKA]
Circuit diagram related to engine start relay
HD465-8, HD605-8 40-729

FAILURE CODE [D1EHKB] 40 TROUBLESHOOTING
FAILURE CODE [D1EHKB]

Action level Failure code Engine Start Relay Output Ground Fault
Failure
L03 D1EHKB (Transmission controller system)
Details of fail- When the controller operates the primary circuit (coil) of the engine start relay, large current flows through the
ure circuit.
q Stops operation of the engine start relay.
Action of con-
troller
Effect on the
Engine will not start.
machine
q The output signal to the engine start relay is examined with the monitor function. (Code: 03706)
Related infor-
mation

1 Defective engine start relay
Between R01 (male) (1) and (2) 290±30 Ω
Resistance

2. Disconnect diode D17, and connect T-adapter to male side.
REMARK
2 Defective diode Measure it with the meter diode range.
Between D17 (male) (2) (-) and (1) (+) No continuity
Continuity With continu-
Between D17 (male) (2) (+) and (1) (-)
ity

2. Disconnect connectors ATCC3, R01, D16, and D17, and connect T-adapter to either
female side.
3
ness Between ground and ATC3 (female) (25) or D16 (female)
Min. 1 MΩ
Resistance (2)
Between ground and D16 (female) (1) or R01 (female) (1) Min. 1 MΩ
4
40-730 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [D1EHKB]
HD465-8, HD605-8 40-731

FAILURE CODE [D1EHKY] 40 TROUBLESHOOTING
FAILURE CODE [D1EHKY]

Action level Failure code Engine Start Relay Output Hot Short Circuit
Failure
L03 D1EHKY (Transmission controller system)
Details of fail- When the controller does not operate the primary circuit (coil) of the engine start relay, the current flows
ure through the circuit.
Action of con-
None in particular
troller
Effect on the The engine will start although the gear shift lever is at a position other than "N".
machine (Protection that is performed when the engine starts does not operate.)
q The output signal to the engine start relay is examined with monitor function. (Code: 03706)
Related infor-
mation

Hot short circuit in wiring 2. Disconnect connector D16, and connect T-adapter to female side.
harness
Voltage Between D16 (female) (2) and ground Max. 4.5 V
2
40-732 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [D1EMKA]
FAILURE CODE [D1EMKA]

Action level Failure code Parking Brake Interlock Relay Output Open Circuit
Failure
L03 D1EMKA (Retarder and hoist controller system)
Details of fail- When the controller operates the primary circuit (coil) of the park brake interlock relay, no current flows
Action of con-
None in particular
troller
Effect on the
Automatic idle stop function does not operate.
machine
mation Procedure: Actuate the auto idle stop function.

Defective parking brake 2. Disconnect connector R27, and connect T-adapter to male side.
1
interlock relay

Open or short circuit in wir- 2. Disconnect connector BRC3, and connect T-adapter to female side.
2
ing harness Between BRC3 (female) (35) and (23)
Resistance 290±30 Ω
Relay coil resistance
If no failure is found with the previous checks, these checks are not required.
Open circuit in wiring har- 2. Disconnect connectors BRC3 and R27, and connect T-adapter to each female side.
3
ness
Resistance
4
Circuit diagram related to parking brake interlock relay
HD465-8, HD605-8 40-733

FAILURE CODE [D1EMKB] 40 TROUBLESHOOTING
FAILURE CODE [D1EMKB]

Action level Failure code Parking Brake Interlock Relay Output Ground Fault
Failure
L03 D1EMKB (Retarder and hoist controller system)
Details of fail- When the controller operates the primary circuit (coil) of the park brake interlock relay, large current flows
q Stops the operation of the parking brake inter-lock relay.
Action of con-
troller
Effect on the
Automatic idle stop function does not operate.
machine
mation Procedure: Actuate the auto idle stop function.

1
interlock relay Between R27 (male) (1) and (2) 290±30 Ω
Resistance

2
(1)

3
4
Circuit diagram related to the parking brake inter-lock relay
40-734 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [D1EMKY]
FAILURE CODE [D1EMKY]

Action level Failure code Parking Brake Interlock Relay Output Hot Short Circuit
Failure
L03 D1EMKY (Retarder and hoist controller system)
Details of fail- When the controller does not operate the primary circuit (coil) of the park brake inter-lock relay, current flows
Action of con-
None in particular
troller
Effect on the q The parking brake remains applied.
machine q Automatic idle stop function does not operate.

Defective parking brake 2. Disconnect connector R27, and connect T-adapter to male side.
1
interlock relay

harness
Voltage Between R27 (female) (1) and ground Max. 4.5 V
3
Circuit diagram related to parking brake interlock relay
HD465-8, HD605-8 40-735

FAILURE CODE [D1FBKB] 40 TROUBLESHOOTING
FAILURE CODE [D1FBKB]

Action level Failure code Solenoid Self-Holding Relay Output Ground Fault
Failure
L03 D1FBKB (Transmission controller system)
Details of fail- When the controller operates the primary circuit (coil) of the solenoid self-hold relay, large current flows
ure through circuit.
q Stops operation of the self-holding relay solenoid.
Action of con-
troller
q Gear speed is held in neutral and the machine cannot travel.
Effect on the
q Radiator fan runs at Maximum speed and damage could occur.
machine
q The fan changes back to its normal direction, when the fan is set in reverse.
q The self-holding relay Solenoid output signal is checked with monitor function. (Code: 03706)
Related infor-
mation

Defective solenoid power
1
holding relay Between R18 (male) (1) and (2) 290±30 Ω
Resistance

Ground fault in wiring har- 2. Disconnect connectors ATC3 and R18, and connect T-adapter to either female side.
2
ness
Resistance Between ground and ATC3 (female) (4) or R18 (female) (1) Min. 1 MΩ

Short circuit in wiring har- 2. Disconnect connectors ATC1 and R18, and connect T-adapter to female side of ATC1.
3
ness
4
40-736 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [D1FBKB]
Circuit diagram related to relay of transmission solenoid power holding relay
HD465-8, HD605-8 40-737

FAILURE CODE [D5ZHL6] 40 TROUBLESHOOTING
FAILURE CODE [D5ZHL6]

Action level Failure code Key SW C Terminal Signal Mismatch
Failure
L01 D5ZHL6 (Machine monitor system)
The Monitor controller recognizes the signal from the key switch terminal C as OFF, when the engine speed is
Details of fail-
500 rpm or higher. The controller also recognizes it as off when the signal voltage of the alternator terminal C
ure
is 8 V or higher.
q None in particular
Action of con-
troller
Effect on the
None in particular
machine
q The Input condition (ON/OFF) of the start switch terminal C is examined with the monitor function. (Code:
Procedure: start the engine.

Open circuit in wiring har- 2. Disconnect connectors MCM1 and R01, and connect T-adapter to each male side.
1
ness
Resistance Between MCM1 (female) (11) and R01 (female) (3) Max. 1 Ω

2. Disconnect connector MCM1, and connect T-adapter to female side.
Defective monitor control-
2
ler Voltage Between MCM1 (female) (11) and ground 20 to 30 V
If no failure is found with these procedures, the monitor controller is defective. (Since this
40-738 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [D5ZHL6]
Circuit diagram related to key switch C terminal signal
HD465-8, HD605-8 40-739

FAILURE CODE [D5ZKKZ] 40 TROUBLESHOOTING
FAILURE CODE [D5ZKKZ]

Action level Failure code Front Brake Cut Valve System Abnormality
Failure
L01 D5ZKKZ (Retarder and hoist controller system)
Details of fail- When the front brake cut valve circuit is energized, no current flows or excessive current flows. Or when not
ure energized, current flows through the circuit.
Action of con-
If the cause of failure is a ground fault, it stops the operation the front brake cut valve .
troller
Effect on the
Front brake cannot be cut off, or it remains cut off.
machine

2. Disconnect connector S03, and connect T-adapter to male side.
Defective front brake cut
1
valve Between S03 (male) (1) and (2) 20 to 60 Ω
Resistance
Between S03 (male) (1), (2) and ground Min. 1 MΩ

Open or short circuit in wir- 2. Disconnect connectors BRC2 and BRC3, and connect T-adapter to each female side.
2
ing harness Between BRC3 (female) (13) and BRC2 (female) (8)
Resistance 20 to 60 Ω
Resistance of solenoid coil
If no failure is found with the procedure on cause 2, this check is not required.
2. Disconnect connectors BRC2 and BRC3, and connect T-adapter to each female side.
3 3. Disconnect connector S03, and connect T-adapter to female side.
ness
Between BRC3 (female) (13) and S03 (female) (2) Max. 1 Ω
Resistance

Ground fault in wiring har- 2. Disconnect connector S03, and connect T-adapter to female side.
4 3. Disconnect connector BRC2, and connect T-adapter to female side.
ness
Resistance Between ground and BRC2 (female) (8) or S03 (female) (1) Min. 1 MΩ
If no failure is found with the procedure on cause 2, this check is not required.
Short circuit in wiring har- 2. Disconnect connectors BRC2 and BRC3, and connect T-adapter to each female side.
5 3. Disconnect connector S03, and connect T-adapter to female side.
ness
Between BRC3 (female) (13) and BRC2 (female) (8) or
between S03 (female) (1) and (2)

2. Disconnect connector S03, and connect T-adapter to female side.
6
harness REMARK
Front brake off switch is in the OFF position.
Voltage Between S03 (female) (1) and (2) Max. 4.5 V
40-740 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [D5ZKKZ]

2. Insert T-adapter into connectors BRC2 and BRC3.
Defective retarder and Front brake off switch: ON 20 to 30 V
7 Between BRC3 (13) and
BRC2 (8) Front brake off switch: OFF Max. 4.5 V
Circuit diagram related to front brake cut valve
HD465-8, HD605-8 40-741

FAILURE CODE [D862KA] 40 TROUBLESHOOTING
FAILURE CODE [D862KA]

Action level Failure code GPS Antenna Open Circuit
Failure
- D862KA (KOMTRAX Plus controller system)
Details of fail-
Open circuit occurs in GPS antenna circuit.
ure
Action of con- q None in particular
Effect on the
GPS positioning system does not work.
machine

Defective connection, or Check that GPS antenna cable is connected with KOMTRAX Plus controller and GPS
1
connector disconnection antenna.
Open circuit in GPS
2 Check if GPS antenna has open circuit.
Antenna
3 Defective GPS Antenna GPS antenna is defective. (Since this is an internal problem, you cannot troubleshoot.)
Defective KOMTRAX Plus If no failure is found with these procedure, KOMTRAX Plus controller is defective. (Since
4
Configuration diagram of GPS antenna
40-742 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DAF0KT]
FAILURE CODE [DAF0KT]

Action level Failure code Monitor Nonvolatile Memory Abnormality
Failure
L03 DAF0KT (Machine monitor system)
Details of fail-
Data will not be recorded to or read from the non-volatile memory of the monitor controller.
ure
q If the primary area of the memory is defective, then Targets the non-volatile memory data that is kept in
Action of con- the backup area.
troller q If the two the primary area and backup area are defective, then the data is directly read from the primary
area of the memory.
Effect on the
Setting values for the service meter, odometer, and others are changed.
machine

Defective monitor control- The monitor controller is defective. (Since this is an internal problem, you cannot trouble-
1
ler shoot.)
HD465-8, HD605-8 40-743

FAILURE CODE [DAF0MB] 40 TROUBLESHOOTING
FAILURE CODE [DAF0MB]

Action level Failure code Monitor ROM Abnormality
Failure
- DAF0MB (Machine monitor system)
Details of fail-
Machine monitor program is rewritten (program error).
ure
Action of con-
troller
Effect on the q Machine monitor display is not reliable.
machine q Data is not transmitted to or received from each controller correctly.

1
ler shoot.)
40-744 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DAF0MC]
FAILURE CODE [DAF0MC]

Action level Failure code Monitor Malfunction
Failure
- DAF0MC (Machine monitor system)
Details of fail-
Defective machine monitor
ure
Action of con-
troller
Effect on the q Machine monitor display is not reliable.
machine q Data is not transmitted to or received from each controller correctly.

1
ler shoot.)
HD465-8, HD605-8 40-745

FAILURE CODE [DAF3KK] 40 TROUBLESHOOTING
FAILURE CODE [DAF3KK]

Action level Failure code Monitor Power Voltage Low Error
Failure
- DAF3KK (Machine monitor system)
Details of fail- The Monitor controller continuous power supply drops to 18 V or lower than when the engine is started or
ure when the secondary steering is in operation.
Action of con-
Prohibits writing to non-volatile memory.
troller
Effect on the q Monitor screen may stay blank.
machine q The display of information decreases and is not reliable.
q If failure code [AB00KE] display, troubleshoot it first.
Related infor- q Machine monitor does not show any failure code.

If circuit breakers 66 and 67, or 68 and 69 are open, the circuit probably has a failure such
1 Defective circuit breaker
as a ground fault.
If the fuse Number 6 in fuse box BT2 is blown, the circuit probably has a failure such as a
2 Defective fuse
ground fault.

2. Make sure that system operating lamp is not illuminated, then turn the battery discon-
nect switch to the OFF position.
4. Turn battery disconnect switch ON.
Between MCM1 (female) (1) and (2) 20 to 30 V
Voltage
Open circuit in wiring har- Between MCM1 (female) (4) and (3) 20 to 30 V
3
ness
Replace fuse No. 6 in the fuse box BT2 if it is broken.
Between battery relay terminal 76 and MCM1 (female) (1)
Max. 1 Ω
and (4)
Resistance
Between MCM1 (female) (2), (3) and ground
Max. 1 Ω
Check the ground terminal ER5 for looseness and rust.

Ground fault in wiring har- 2. Remove fuse No.6 in fuse box BT2.
4 3. Disconnect connector MCM1, and connect T-adapter to female side.
ness
Resistance Between ground and BT2-12 or MCM1 (female) (1) and (4) Min. 1 MΩ
Defective monitor control- If no failure is found by the previous checks, the monitor controller is defective. (Since this
5
40-746 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DAF3KK]
Circuit diagram related to battery relay
HD465-8, HD605-8 40-747

FAILURE CODE [DAF8KB] 40 TROUBLESHOOTING
FAILURE CODE [DAF8KB]

Action level Failure code Camera Power Supply Short Circuit
Failure
L03 DAF8KB (Machine monitor system)
Details of fail- When the controller does not output the power from the rearview monitor to the camera, or the output power
ure voltage is 10 V or higher.
q Stops the camera power supply.
Action of con-
troller
Effect on the
Camera image is not shown on the machine monitor.
machine

1 Defective camera 2. Disconnect camera connector RVC1, and Turn the start switch to the ON position.
If the failure code clears after you disconnect, there is an internal problem in the camera.

2. Disconnect connector RMN2, and connect T-adapter to male side.
2 Defective rearview monitor 3. Turn the start switch to the ON position.
Voltage Between RMN2 (male) (1) and ground 6 to 10 V

Ground fault in wiring har- 2. Disconnect the connectors RMN2 and camera connector RVC1.
3 3. Disconnect connector RMN2, and connect T-adapter to female side.
ness
Resistance Between RMN2 (female) (1) and ground Min. 1 MΩ

2. Disconnect the camera connector RVC1.
3. Insert T-adapter into connector RMN2.
harness
(Before you troubleshoot, disconnect camera and make sure the system goes back to
normal)
Voltage Between RMN2 (1) and (5) Max. 10 V
Circuit diagram related to camera power supply
40-748 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DAFDKB]
FAILURE CODE [DAFDKB]

Action level Failure code 12 V Power Output Hot Short or Ground Fault (Monitor)
Failure
L01 DAFDKB (Machine monitor system)
Details of fail- When the start switch is turned to the ON position, 12 V power drops to 8 V and lower, or increase to 14 V or
ure higher.
q Stops the supply of 12 V output power.
Action of con-
troller
q Switch panel does not operate.
Effect on the q LED unit does not illuminate or illuminates incorrectly.
machine q When the engine start lock is activated, the engine will not start, because it is not possible to enter a pass-
word.
q If failure code [DAF3KK] (Main power voltage low) is generated, troubleshoot it first.
Related infor-
mation

2. Disconnect connectors MCM2, DPC2, and OPM, and connect T-adapter to either
1
ness
Between ground and each of MCM2 (female) (107), DPC2
(female) (1), and OPM (female) (1)

Hot short circuit in wiring 2. Disconnect connector MCM2, and connect T-adapter to female side.
harness
Voltage Between MCM2 (female) (107) and (99) Max. 1 V

Defective monitor control- 2. Disconnect connector MCM2, and connect T-adapter to male side.
ler
Voltage Between MCM2 (male) (107) and (99) Approx. 12 V
HD465-8, HD605-8 40-749

FAILURE CODE [DAFDKB] 40 TROUBLESHOOTING
Circuit diagram related to monitor controller 12 V output power supply
40-750 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DAFGMC]
FAILURE CODE [DAFGMC]

Action level Failure code GPS Module Malfunction
Failure
- DAFGMC (KOMTRAX Plus controller system)
Details of fail-
No position data is sent from GPS module within KOMTRAX Plus controller.
ure
Action of con- q None in particular
Effect on the
GPS positioning system does not work.
machine

Defective KOMTRAX Plus GPS module of KOMTRAX Plus controller may be defective. (Since this is an internal
1
controller problem, you cannot troubleshoot.)
HD465-8, HD605-8 40-751

FAILURE CODE [DAFLKA] 40 TROUBLESHOOTING
FAILURE CODE [DAFLKA]

Action level Failure code System Operating Lamp Open Circuit (Monitor)
Failure
- DAFLKA (Machine monitor system)
The Monitor controller sensed an open circuit, because the output line voltage of the system operation lamp is
Details of fail-
5 V or lower. This occurs for approximately 3 seconds when the monitor controller is not operational after start
ure
switch is turned to the ON position.
Action of con-
troller
Effect on the
System operating lamp may not illuminate.
machine
q Do not turn the battery disconnect switch to "the OFF" position while the system operation lamp
is illuminated. If the battery disconnect switch is set to the OFF position, the data kept in the mon-
itor controller memory is lost.
q Although the monitor controller cannot turn the system operation lamp on, there is no problem unless the
Related infor-
battery disconnect switch is turned OFF.
mation
q An open circuit is sensed because none of the controllers operate the system operation lamp for 3 sec-
onds after the start switch is turned ON.

q If the room lamp illuminates, this check is not required.
1 Defective fuse
q If the fuse No. 14 in the fuse box BT4 is broken, the circuit probably has ground fault.

2 3. Remove the fuse No.14 in fuse box BT4.
ness
4. Disconnect connectors MCM1 and OPL, and connect T-adapter to each female side.
Between MCM1 (female) (57) and OPL (female) (2) Max. 1 Ω
Resistance
Between BT4-28 and OPL (female) (1) Max. 1 Ω

Ground fault in wiring har- the start switch OFF
3
ness 3. Remove fuse No.14 in fuse box BT4.
4. Disconnect connector OPL, and connect T-adapter to female side.
Resistance Between ground and BT4-28 or OPL (female) (1) Min. 1 MΩ
4
40-752 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DAFLKA]
HD465-8, HD605-8 40-753

FAILURE CODE [DAFLKA] 40 TROUBLESHOOTING
40-754 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DAFLKB]
FAILURE CODE [DAFLKB]

Action level Failure code System Operating Lamp Short Circuit (Monitor)
Failure
- DAFLKB (Machine monitor system)
Details of fail- Monitor controller sensed a short circuit because the output voltage does not decrease below specified volt-
ure age when the monitor controller operates the system operation lamp.
q Stops the system operation lamp.
Action of con-
troller
Effect on the
System operating lamp may not illuminate.
machine
q Do not turn the battery disconnect switch to "the OFF" position while the system operation lamp is illumi-
nated. If the battery disconnect switch is set to the OFF position, the data kept in the monitor controller
memory is lost.
Related infor-
q Although the monitor controller cannot turn the system operation lamp on, there is no problem unless the
mation
battery disconnect switch is turned OFF.

1
2
HD465-8, HD605-8 40-755

FAILURE CODE [DAFLKB] 40 TROUBLESHOOTING
40-756 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DAFLKB]
HD465-8, HD605-8 40-757

FAILURE CODE [DAFQKR] 40 TROUBLESHOOTING
FAILURE CODE [DAFQKR]

Action level Failure code CAN 2 Defective Communication (Monitor)
Failure
- DAFQKR (KOMTRAX Plus controller system)
Details of fail- KOMTRAX Plus controller does not recognize the monitor controller on CAN2 communication line (KOM-
ure NET/c).
Action of con-
None in particular
troller
Effect on the
Settings related to the KOMTRAX Plus are disabled on the monitor.
machine
q The ACC signal from the start switch informs each controller of the start of CAN communication.
q Failure code is displayed on the machine monitor by CAN communication. If CAN communication for the
monitor controller has a failure, failure code [DAFQKR] is not displayed and can only be checked via the
KOMTRAX communication system.
Related infor-
q Since each controller and the machine monitor, (meter unit) are connected directly to the battery, they
mation
have power with the start switch turned OFF.
q After the repair is completed, make sure that the failure code is not shown in KOMTRAX using these pro-
cedures.

Defective power supply to
1 Perform troubleshooting for failure code [DAF3KK].
monitor controller
Defective CAN communi-
2 Perform troubleshooting for cause 4 and subsequent causes for failure code [DB2QKR].
cation
40-758 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DAQ0KK]
FAILURE CODE [DAQ0KK]

Action level Failure code Main Power Voltage Low Error (T/M Controller)
Failure
L03 DAQ0KK (Transmission controller system)
Details of fail- Other than when the engine turns with the start switch ON, or when secondary steering is in operation, the
ure voltage drops to 18 V or less.
Action of con- q Holds current gear speed.
troller q Shifts the transmission to neutral and moves the shift lever to neutral.
q When supply voltage is lost (open circuit), the transmission suddenly shifts to neutral while the machine
is in operation. The machine will not start until voltage supply goes back to normal.
Effect on the
q Radiator fan runs at Maximum speed and damage could occur.
machine
q The fan changes back to its normal direction, when the fan is set in reverse.
q The machine can be moved when voltage is low. However, the clutch may slip due to overload.
q If the failure code [AB00KE] (charge voltage low) is generated, troubleshoot it first.
Related infor-
mation

1 Defective battery
Defective circuit breaker or If circuit breakers 66, 67, 68 or 69 are opened, or fuse Number 5 of the fuse BT2 is blown,
2
fuse the circuit may have a ground fault.

3. Disconnect connector ATC3, and connect T-adapter to female side.
REMARK
If voltage appears between battery relay terminal 76 and ground but not between ground
and each of ATC3 (1) and (11), wiring harness or fuse has open circuit.
Between battery relay terminal 76 and ground 20 to 30 V
Open circuit in wiring har- Voltage
3
ness Between ATC3 (female) (1), (11) and ground 20 to 30 V
If no failure is found with the previous checks, these checks are not required.
Between ground and each of ATC3 (female) (21), (31),
Max. 1 Ω
Resistance (32), and (33)
Between ATC3 (1), (11) and battery relay terminal 76 Max. 1 Ω

Ground fault in wiring har- nect switch to the OFF position.
4 3. Remove fuse No.5 in fuse box BT2.
ness
Resistance Between ATC3 (female) (1), (11) and ground Min. 1 MΩ
HD465-8, HD605-8 40-759

FAILURE CODE [DAQ0KK] 40 TROUBLESHOOTING

Short circuit in wiring har- 3. Remove fuse No.5 in fuse box BT2.
5
ness
Between ATC3 (female) (1) and each pin other than pin (1)
and (11)

3. Insert T-adapter into the connector ATC3.
Defective transmission 4. Turn the battery disconnect switch ON.
6
controller 5. Turn the start switch to the ON position.
Voltage Between ATC3 (1), (11) and (21), (31), (32), (33) 20 to 30 V
If no failure is found with the previous procedures, the transmission controller is defective.
40-760 HD465-8, HD605-8

Circuit diagram related to Transmission controller
HD465-8, HD605-8 40-761

FAILURE CODE [DAQ0KT] 40 TROUBLESHOOTING
FAILURE CODE [DAQ0KT]

Action level Failure code T/M Controller Read Only Memory Abnormality
Failure
L01 DAQ0KT (Transmission controller system)
Details of fail- q Non-volatile memory in the transmission controller is defective.

ure q When the start switch is turned to the OFF position, the end process is not completed successfully.
q Controls the machine using default values of the machine model selection and option settings.
Action of con-
troller
Effect on the q Machine control parameters change and transmission shifting shock may increase.
machine q Maximum speed limit parameters change and the machine may not start.
q Perform initial set up and adjustments similar to those required when the transmission controller is re-
Related infor- placed. (See TEST AND ADJUST, "SET AND ADJUST EACH EQUIPMENT".)

Defective transmission Since this is an internal defect, you cannot troubleshoot. (If there is no visible failure on
1
controller machine, the controller may be used as it is after initial setting or initial adjustment.)
40-762 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DAQ0MC]
FAILURE CODE [DAQ0MC]

Action level Failure code T/M Controller Malfunction
Failure
- DAQ0MC (Transmission controller system)
Details of fail-
Controller shows incorrect control (not the expected control).
ure
Action of con-
Set the controller CPU, and then start it.
troller
Effect on the q Machine goes back to initial condition as that when the start switch is turned to ON position.
machine q Gear speed is set to neutral until the gear shift lever is moved to N position.

Defective transmission Defective transmission controller (Since this is an internal defect, troubleshooting cannot
1
controller be performed.)
HD465-8, HD605-8 40-763

FAILURE CODE [DAQ1KA] 40 TROUBLESHOOTING
FAILURE CODE [DAQ1KA]

Action level Failure code Key SW ACC Main Power Supply Open Circuit (T/M Controller)
Failure
L03 DAQ1KA (Transmission controller system)
Details of fail-
Key switch signal is "OFF" on the transmission controller, while the retarder and hoist controller is "ON".
ure
Transmission controller recognizes that the start switch is turned to the OFF position and performs these pro-
Action of con- cedures.
troller q Holds current gear speed.
q Shifts the transmission to neutral and moves the shift lever to neutral.
q Gear shift selection is not available.
Effect on the
q If gear shift lever is set to "N" during travel, although a position other that "N" is selected, the gear selection
machine
is not performed.

2. Disconnect the connectors ATC3 and ESS, and connect T-adapters into each female
1
ness
Between ATC3 (female) (14) and ESS (female) (4) Max. 1 Ω
Resistance
Between ATC3 (female) (24) and ESS (female) (4) Max. 1 Ω

2
controller Voltage Between ATC3 (14), (24) and (21), (31), (32), (33) 20 to 30 V
40-764 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DAQ1KA]
Circuit diagram related to transmission controller key switch ACC signal
HD465-8, HD605-8 40-765

FAILURE CODE [DAQ1KA] 40 TROUBLESHOOTING
Circuit diagram related to transmission controller key switch ACC signal (For machines equipped with emergency
engine stop switch)
40-766 HD465-8, HD605-8

FAILURE CODE [DAQ2KK]

Action level Failure code Solenoid Power Voltage Low Error (T/M Controller)
Failure
L03 DAQ2KK (Transmission controller system)
Details of fail- The Solenoid supply voltage that appears at transmission controller pins 2, 12, and 22 is 18 V or lower while
ure the controller supply voltage is normal. (directly from the battery)
Action of con- q Holds current gear speed.
troller q Shifts the transmission to neutral and moves the shift lever to neutral.
q If the voltage drops to 0 V, the transmission will suddenly shift to neutral while the machine is in operation.
Effect on the
The gears will not shift, although you move the gear shift lever to a position other than N.
machine
q If voltage drops, clutches may slip relative to the load.
q If the failure code [D1FBKB] is shown, troubleshoot it first.
q If circuit breakers 66, 67, 68, or 69 are opened, or fuse number 5 in fuse box BT2 is blown, failure code
Related infor-
[DAQ0KK] is shown.
mation

Between R18 (male) (1) and (2) 290±30 Ω
Resistance

Defective solenoid power 2. Replace solenoid power holding relay R18 with a normal one.
1
holding relay
Does the Defective
The machine goes back to normal.
machine go relay R18
back to nor-
mal after you
replace R18 Machine does not go back to normal. Relay R18 is
solenoid hold normal.
relay?

2. Turn the battery disconnect switch to OFF position.
3. Disconnect the connectors R18 and ATC3, and insert T-adapters into each female
side.
Between ATC3 (1) and R18 (5) Max. 1 Ω
2 Between ATC3 (2) and R18 (3) Max. 1 Ω
ness
Resistance
Between ATC3 (21), (31), (32), and (33), and R18 (2) Max. 1 Ω

Ground fault in wiring har- nect switch to the OFF position.
3
ness 3. Disconnect connectors ATC3 and R18, and connect T-adapter to either female side.
Between ground and ATC3 (female) (2), (12), (22) or R18
(female) (3)
HD465-8, HD605-8 40-767

FAILURE CODE [DAQ2KK] 40 TROUBLESHOOTING

Short circuit in wiring har- nect switch to the OFF position.
4
ness 3. Disconnect connectors ATC3 and R18, and connect T-adapter to female side.
Between ATC3 (female) (2) and each pin other than pin (2),
(12) and (22)

2. Turn the battery disconnect switch to OFF position.
Defective transmission 4. Turn the start switch to the ON position.
5
controller
Voltage Between ATC3 (4) and (21), (31), (32), and (33) 20 to 30 V
40-768 HD465-8, HD605-8

Circuit diagram related to transmission solenoid power supply
HD465-8, HD605-8 40-769

FAILURE CODE [DAQ9KQ] 40 TROUBLESHOOTING
FAILURE CODE [DAQ9KQ]

Action level Failure code Model Selection Signal Mismatch (T/M Controller)
Failure
L03 DAQ9KQ (Transmission controller system)
Details of fail-
Model information sent from the machine monitor does not match that stored in the transmission controller.
ure
q Shifts the gear speed to neutral.
Action of con-
troller
Effect on the Gear speed is set to neutral and the gear does not shift, although you move the gear shift lever to a position
machine other than N.

The machine model setting on the machine monitor is probably incorrect. After you
Incorrect model type set-
1 replace the machine monitor or transmission controller, always set the model correctly.
ting on machine monitor
For details, see TEST AND ADJUST, "DEFAULT MENU".
Incorrect transmission con- Incorrect transmission controller may be installed. Check part No. and install correct
2
troller installed transmission controller.
If no failure is found with the previous procedures, the machine monitor or transmission
3 ler or transmission control-
ler
40-770 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DAQLKA]
FAILURE CODE [DAQLKA]

Action level Failure code System Operating Lamp Open Circuit
Failure (Transmission controller)
- DAQLKA (Transmission controller system)
The transmission controller senses an open circuit after the start switch is turned to the ON position. The out-
Details of fail-
put line voltage for the system operation lamp is 5 V or lower for approximately 3 seconds when the transmis-
ure
sion controller is not in operation.
Action of con-
troller
Effect on the
System operating lamp may not illuminate while the controller performs the record procedure
machine
q If the battery disconnect switch is set to the "OFF" position while the controller records Data, the fan
stops suddenly and damage could occur. In addition, the initial learn data is lost, and results in in-
creased shift shocks.
q Although the transmission controller, cannot turn on the system operation lamp. No problems will occur
Related infor- as long as the battery disconnect switch is turned OFF 3 minutes after the start switch is turned OFF.
mation q Do not turn the battery disconnect switch to OFF position while the system operating lamp is lit.
q An open circuit is sensed because none of the controllers operate the system operation lamp for 3 sec-
onds after the start switch is turned ON.

1 Defective fuse 3. Remove fuse Number 14 in fuse box BT4, and visually examine for blown out.
4. If the fuse is not blown, perform a continuity test to make sure.

2 3. Remove fuse Number 14 in fuse box BT4.
ness
4. Disconnect connectors ATC3, and OPL, and connect T-adapter to each female side.
Resistance
Between ATC3 (female) (34) and OPL (female) (2) Max. 1 Ω

Ground fault in wiring har- the start switch OFF
3
ness 3. Remove fuse Number14 in fuse box BT4.
4
HD465-8, HD605-8 40-771

FAILURE CODE [DAQLKA] 40 TROUBLESHOOTING
40-772 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DAQLKA]
HD465-8, HD605-8 40-773

FAILURE CODE [DAQLKB] 40 TROUBLESHOOTING
FAILURE CODE [DAQLKB]

Action level Failure code System Operation Lamp Short Circuit
Failure (Transmission controller)
- DAQLKB (Transmission controller system)
Details of fail- Transmission controller detected a short circuit because the output voltage does not decrease below speci-
ure fied voltage when the transmission controller operates the system operation lamp.
Action of con-
troller
q When the controller operates the system operation lamp, large current flows through the circuit and may
Effect on the
blow out the controller.
machine
q System operating lamp may not illuminate while the controller performs the record procedure
q If the battery disconnect switch is set to the "OFF" position while the controller records Data, the fan stops
suddenly and damage could occur. In addition, the initial learn data is lost, and results in increased shift
shocks.
Related infor- q Although the transmission controller, cannot turn on the system operation lamp. No problems will occur
mation as long as the battery disconnect switch is turned OFF 3 minutes after the start switch is turned OFF.
REMARK
Voltage between pin (2) on the female side and ground is 20 V or more when the start switch is ON and con-
nector OPL is open. You cannot check for a hot short circuit.

1
2
40-774 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DAQLKB]
HD465-8, HD605-8 40-775

FAILURE CODE [DAQLKB] 40 TROUBLESHOOTING
40-776 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DAQQKR]
FAILURE CODE [DAQQKR]

Action level Failure code CAN2 Defective Communication (T/M Controller)
Failure
L03 DAQQKR (Detected by monitor controller) (Machine monitor system)
Details of fail-
Monitor controller does not recognize transmission controller over CAN 2 communication line (KOMNET/c).
ure
Action of con-
Does not update communication information with the transmission controller.
troller
q Failure codes related to the transmission controller are not shown.
Effect on the q Monitor data related to the transmission controller is not updated.
machine q Fan rotating in reverse is disabled.
q Adjustment function is not available.
q There are 6 different failure codes, [D8VQKR], [DAQQKR], [DB1QKR], [DB2QKR], [DAZQKR]
and [DSJ0KR]. They are used for a defective CAN communication on CAN2 sensed by the mon-
itor controller. When all of these 6 failure codes are shown, a ground fault, short circuit or hot short
circuit in wiring harness could be the cause. (CAN communication line) In such case, since the air
conditioner is also operated through the CAN communication. Examine whether the air condition-
er is operable (ON/OFF and the airflow adjustment) on the air conditioner screen.
Related infor-
mation
REMARK
Machine with ABS system also displays failure code [DBCQKR].
q If air conditioner is operable, wiring harness (CAN communication line) does not have ground fault, short
circuit, or hot short circuit.
q Since each controller and the machine monitor, (meter unit) are connected directly to the battery, they
have power with the start switch turned OFF.

1 Perform troubleshooting for failure code [DAQ0KK].
Defective CAN2 communi-
2 Perform checks on causes 4 to 9 for failure code [DB2QKR].
cation line
3
4
HD465-8, HD605-8 40-777

FAILURE CODE [DAQRKR] 40 TROUBLESHOOTING
FAILURE CODE [DAQRKR]

Action level Failure code CAN1 Defective Communication (T/M Controller)
Failure
L03 DAQRKR (Detected by monitor controller) (Machine monitor system)
Details of fail-
Monitor controller does not recognize transmission controller over CAN 1 communication line (KOMNET/r).
ure
Action of con- q Hides the pointer for the torque converter oil temperature gauge on the screen.
troller q Shows the speed meter at "00".
q Information obtained from the transmission controller is not shown, special functions commanded from it
Effect on the are not operated, or received data is no longer updated.
machine q Oil temperature of the torque converter cannot be seen.
q Travel speed is not recognized.
q Other failure codes for a defective CAN communication through CAN 1 line sensed by monitor controller
are [DB1RKR], [DBVRKR], and [DB2RKR]. When the failure codes [DB1RKR], [DBVRKR], or [DB2RKR]
are also shown. A ground fault, short circuit, or hot short in wiring harness (CAN communication line) could
be the cause.
Related infor- REMARK
mation Machine with ABS system also displays failure code [DBCRKR].
q CAN1 terminate resistor is located in the monitor controller, on the operator's cab side.
q Since each controller and the monitor controller are connected directly to the battery, they are supplied
with power although the start switch is turned OFF.

Defective power supply
1 system to transmission Perform troubleshooting for failure code [DAQ0KK].
controller
2 Perform checks on causes 2 to 7 for failure code [DB2RKR].
cation line
3
4
40-778 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DAQRMA]
FAILURE CODE [DAQRMA]

Action level Failure code Option Selection Inconsistency (T/M Controller)
Failure
L03 DAQRMA (Transmission controller system)
Details of fail- When the start switch is turned to the ON position, option setting information sent from the machine monitor
ure differs from that stored in the transmission controller.
Action of con-
q Controls with the option settings stored in the controller.
troller
q Not restored until the start switch is turned to the OFF position.
Effect on the Gear speed is set to neutral and the gear does not shift, although you move the gear shift lever to a position
machine other than N.
q Perform initial setting and initial adjustment similar to those required when transmission controller is re-
Related infor- placed.

Defective option setting of Option setting of the machine monitor is probably incorrect. To set the option setting cor-
1
machine monitor rectly, see TEST AND ADJUST, DEFAULT MENU.
If no failure is found with the previous procedures, the machine monitor or transmission
2 ler or transmission control-
ler
HD465-8, HD605-8 40-779

FAILURE CODE [DAQV00] 40 TROUBLESHOOTING
FAILURE CODE [DAQV00]

Action level Failure code Neutral Coast Caution
Failure
- DAQV00 (Transmission controller system)
Details of fail- q Set the gear shift lever to N position while you travel at 4 km/h or faster.
ure q In downhill travel with the gear shift lever in the "N" position, travel speed exceeds 17 km/h.
Action of con- q Operates the alarm buzzer.
troller q Performs gear shift the same way as when you select the gear shift "D" position.
Effect on Gear speed is not shifted to neutral until the travel speed drops to 4 km/h or less, although you moved the
machine gear shift lever to N position.
Related infor-
mation

Instruct operators on the proper operation procedures.
Operation error of the gear
1 q Do not set the gear shift lever to the "N" position while you travel at 4 km/h or faster.
shift lever
q Do not travel downhill with the gear shift lever in the "N" position.
2
40-780 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DAQW00]
FAILURE CODE [DAQW00]

Action level Failure code Neutral Over Speed Caution
Failure
- DAQW00 (Transmission controller system)
Details of fail-
In downhill travel with the gear shift lever in the "N" position, travel speed exceeds 4 km/h.
ure
Action of con-
Operates the alarm buzzer.
troller
Effect on
None in particular
machine
Related infor-
mation

Operation error of the gear q Instruct operators on the proper operation procedures.
1
shift lever q Do not travel downhill with the gear shift lever in the "N" position.
2
HD465-8, HD605-8 40-781

FAILURE CODE [DAZ9KQ] 40 TROUBLESHOOTING
FAILURE CODE [DAZ9KQ]

Action level Failure code Model Selection Signal Mismatch (A/C)
Failure
- DAZ9KQ (Machine monitor system)
Details of fail- Machine type data recorded in the monitor controller and in the air conditioner controller do not agree.
ure Replaced monitor controller or air conditioner controller has a wrong part number.
Effect of con-
None in particular
troller
Effect on the
Air conditioner does not operate correctly.
machine
q Monitor function Code 55201 examines the control data of the air conditioner controller (machine type and
Related infor- sequence). (Control data must be 05, which indicates the HD articulated dump truck.)
mation q After the repair is completed, check that the failure code is removed by the procedures that follow.

1 Defective monitor controller (Wrong machine type is recorded)
ler
Defective air conditioner
2 Defective air conditioner controller (Wrong machine type is recorded)
controller
40-782 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DAZQKR]
FAILURE CODE [DAZQKR]

Action level Failure code CAN 2 Defective Communication (A/C ECU)
Failure
L01 DAZQKR (Sensed by monitor controller) (Machine monitor system)
Details of fail- Monitor controller does not recognize the air conditioner controller on CAN 2 communication line (KOM-
ure NET/c).
Effect of con-
Does not update communication information with the air conditioner controller.
troller
q Failure codes related to the air conditioner controller are not shown.
Effect on the q Data used to monitor, (related to the air conditioner controller) are not up-to-date.
machine q Air conditioner is not controlled. (Air does not blow out.)
q Air conditioner operation screen of the machine monitor is not shown correctly.
q ACC signal from the start switch informs each controller of the start of the CAN communication.
q 6 different failure codes, [DBVQKR], [DAQQKR], [DB1QKR], [DB2QKR], [DAZQKR] and [DSJ0KR] are used
for defective CAN communication by CAN 2 found by the monitor controller. When all 6 of these failure codes
are shown, ground fault, short circuit or hot short circuit in wiring harness is suspect. (CAN communication line
is suspect)
Related infor-
mation
REMARK
q Each controller and the machine monitor are connected directly to the battery. They are supplied with
power although the start switch is turned to OFF.
q After the repair is completed, check that the failure code is removed by the procedures that follow.

1 Defective fuse If fuse number 3 in fuse case BT2 is blown, the circuit probably has a ground fault.
2 Troubleshoot with Chapter 80, "TROUBLESHOOTING OF ELECTRICAL SYSTEM".
air conditioner controller
cation line
Defective monitor control- If there is no failure found with the previous checks, the monitor controller is defective.
4
ler (Since this is an internal problem, you cannot troubleshoot.)
Defective air conditioner If there is no failure found with the previous checks, the air conditioner controller is defec-
5
controller tive. (Since this is an internal problem, you cannot troubleshoot.)
Circuit diagram related to air conditioner controller
HD465-8, HD605-8 40-783

FAILURE CODE [DB10KT] 40 TROUBLESHOOTING
FAILURE CODE [DB10KT]

Action level Failure code RHC Read Only Memory Abnormality
Failure
L01 DB10KT (Retarder and hoist controller system)
Details of fail-
Non-volatile memory in the controller is abnormal.
ure
q Controls the machine using already set values of the machine type selection with additions and their set-
Effect of con- tings.
troller q Although the cause of failure is eliminated, the machine does not resume normal operation until the start
switch is turned OFF.
q A shock occurs when the dump body is lowered.
Effect on the
q Secondary steering individual check function does not operate correctly.
machine
q Travel speed for ARSC is set to the already set value.
Related infor- After the repair is completed, check that the failure code is removed by the procedures that follow.
No. Cause Procedure, test location, specifications, and remarks

Defective retarder and Retarder and hoist controller is defective. (Since this is an internal defect, you cannot trou-
1
hoist controller bleshoot.)
40-784 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DB10MC]
FAILURE CODE [DB10MC]

Action level Failure code RHC Malfunction
Failure
- DB10MC (Retarder and hoist controller system)
Details of fail-
Retarder and hoist controller malfunction
ure
Effect of con-
None in particular
troller
Effect on the
System does not operate correctly.
machine

Defective retarder and Retarder and hoist controller is defective. (Since this is an internal defect, you cannot trou-
1
hoist controller bleshoot.)
HD465-8, HD605-8 40-785

FAILURE CODE [DB11KA] 40 TROUBLESHOOTING
FAILURE CODE [DB11KA]

Action level Failure code Key SW ACC Signal Open Circuit (RHC)
Failure
L03 DB11KA (Retarder and hoist controller system)
Details of fail- Key switch signal recognized by the retarder and hoist controller is "OFF" while that recognized by the trans-
ure mission controller is "ON".
Effect of con-
Cancel controls of KTCS, ARSC, overrun prevention retarder, and automatic suspension.
troller
Effect on the q KTCS, ARSC, and over run prevent retarder do not operate.
machine q The automatic suspension is in moderate mode.

2. Check that system operating lamp is not illuminated, and then turn the battery discon-
nect switch to OFF position.
1 Defective fuse 3. Remove fuse No. 12 in the fuse box BT3, and visually check if it is blown.
4. If the fuse is not blown, perform a continuity test to see if it is broken.
q If the fuse is blown, troubleshoot for a Ground fault in wiring harness.

3. Disconnect connector ESS, and connect T-adapter to the male side.
Defective engine shut-
2 Between ESS (male) (1) and (2) Max. 1 Ω
down secondary switch
Between ESS (male) (4) and (5) Max. 1 Ω
Resistance
Between ESS (male) (1) and ground Min. 1 MΩ
Between ESS (male) (4) and ground Min. 1 MΩ

2. Check that system operating lamp is not lit, and then turn the battery disconnect switch
to OFF position.
3. Disconnect connector BRC3, and connect T-adapter to the female side.
Between BRC3 (female) (14) and (21) 20 to 30 V
Voltage
Open circuit in wiring har- Between BRC3 (female) (24) and (31) 20 to 30 V
3
ness
If no failure is found by the previous checks, this check is not required.
3. Disconnect connectors BRC3 and ESS, and connect T-adapter to the female side.
Between BRC3 (female) (14) and ESS (female) (4) Max. 1 Ω
Resistance
40-786 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DB11KA]

to OFF position.
Defective retarder and 5. Turn the start switch to the ON position.
4
hoist controller
Between BRC3 (14) and (21) 20 to 30 V
Voltage
If no failure is found by the previous checks, the retarder and hoist controller is defective.
(Since this is an internal defect, you cannot troubleshoot.)
HD465-8, HD605-8 40-787

FAILURE CODE [DB11KA] 40 TROUBLESHOOTING
Circuit diagram related to retarder and hoist controller key switch ACC signal
40-788 HD465-8, HD605-8

FAILURE CODE [DB11KA] (For machines equipped with emergency engine
40 TROUBLESHOOTING stop switch)
FAILURE CODE [DB11KA] (For machines equipped with emer-

Action level Failure code Key SW ACC Signal Open Circuit (RHC)
Failure
L03 DB11KA (Retarder and hoist controller system)
Details of fail- Key switch signal recognized by the retarder and hoist controller is "OFF" while that recognized by the trans-
ure mission controller is "ON".
Effect of con-
Cancel controls of KTCS, ARSC, overrun prevention retarder, and automatic suspension.
troller
Effect on the q KTCS, ARSC, and over run prevent retarder do not operate.

1 Defective fuse 3. Remove fuse No. 12 in the fuse box BT3, and visually check if it is blown.
4. If the fuse is not blown, perform a continuity test to see if it is broken.

3. Disconnect connector ESS, and connect T-adapter to the male side.
2 Between ESS_F (male) (1) and (2) Max. 1 Ω
Between ESS_F (male) (4) and (5) Max. 1 Ω
Resistance
Between ESS_F (male) (1) and ground Min. 1 MΩ
Between ESS_F (male) (4) and ground Min. 1 MΩ

2. Disconnect connectors SES, ML_01, and ESS, and connect T-adapter to each female
side.
Between ESS_M (male) (1) and ESS_F (female) (1) Max. 1 Ω
Defective emergency
3 Between SES (female) (1) and (2) Max. 1 Ω
engine stop switch
Resistance Between ML01_M (female) (5) and (6) Max. 1 Ω
Between ESS_M (male) (1) and ground Min. 1 MΩ
Between SES (female) (1) and ground Min. 1 MΩ
Between ML01_M (female) (6) and ground Min. 1 MΩ
HD465-8, HD605-8 40-789

stop switch) 40 TROUBLESHOOTING

to OFF position.
Between BRC3 (female) (14) and (21) 20 to 30 V
Voltage
Open circuit in wiring har- Between BRC3 (female) (24) and (31) 20 to 30 V
4
ness
If no failure is found by the previous checks, this check is not required.
3. Disconnect connectors BRC3 and ESS, and connect T-adapter to the female side.
Resistance

to OFF position.
Defective retarder and 5. Turn the start switch to the ON position.
5
hoist controller
Voltage
40-790 HD465-8, HD605-8

Circuit diagram related to retarder and hoist controller key switch ACC signal (For machines equipped with emer-
HD465-8, HD605-8 40-791

FAILURE CODE [DB12KK] 40 TROUBLESHOOTING
FAILURE CODE [DB12KK]

Action level Failure code Solenoid Power Voltage Low Error (RHC)
Failure
L03 DB12KK (Retarder and hoist controller system)
Details of fail-
Solenoid power supply voltage is 18 V or below, while the controller direct power supply voltage is normal.
ure
Effect of con- q Stops to operate the hoist selector solenoid and the hoist EPC solenoid.
troller q Cancel controls of KTCS, ARSC, and automatic suspension.
q Retarder does not operate correctly.
Effect on the q Dump body does not move.
machine q KTCS and ARSC do not operate.
q The automatic suspension is in moderate mode.
q If failure code [DAQ0KK] and/or [DAQ2KK] (transmission controller power supply) is shown, troubleshoot
Related infor- for it first.
Turn the start switch to the ON position.

Defective circuit breaker or The circuit breaker between connectors 64 and 65, or the fuse No. 2 of the fuse BT4 is
1
fuse blown. The circuit may have a ground fault.

to OFF position.
REMARK
The voltage of battery relay connector 77 is normal and the voltages of connector BRC3
(2), (12), and (22) are not normal. There is an open circuit in wiring harness between bat-
tery relay connector 77 and each of the connectors BRC3 (female) (2), (12), and (22).
2 Between battery relay terminal 77 and ground 20 to 30 V
ness
Voltage Between ground and BRC3 (female) (2), (12), (22)
20 to 30 V
Inspect for a loose or rusty ground terminal ER1.

to OFF position.
Between ground and BRC3 (female) (21), (31), (32), (33)
Resistance Make sure the ground connector ER5 is not loose or has Max. 1 Ω
rust.

3. Remove fuses No. 2 thru 10 in fuse case BT4, and fuses No. 1 thru 4 in fuse case BT5.
3 4. Disconnect connectors BRC3, J04, and J13, and connect T-adapter to each female
ness
side of BRC3.
Between ground and BRC3 (female) (2), (12), (22) Min. 1 MΩ
Resistance
Between BT4-3 and ground Min. 1 MΩ
40-792 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DB12KK]

Defective retarder and 4. Turn battery disconnect switch ON.
4
hoist controller 5. Turn the start switch to the ON position.
Voltage Between ground and BRC3 (2), (12), (22) 20 to 30 V
HD465-8, HD605-8 40-793

Circuit diagram related to power supply to retarder and hoist controller solenoid
40-794 HD465-8, HD605-8

FAILURE CODE [DB13KK]

Action level Failure code Main Power Voltage Low Error (RHC)
Failure
L03 DB13KK (Retarder and hoist controller system)
Details of fail- Direct power supply voltage drops to 18 V or lower. Other than when the engine is turned with the start switch
ure at ON or when the secondary steering is in operation.
q Stops to operate the hoist selector solenoid and the hoist EPC solenoid.
Effect of con-
q Cancel KTCS control.
troller
q Cancel controls of ARSC, automatic suspension, and overrun prevention retarder.
q Retarder does not operate correctly.
Effect on the q Dump body does not move.
machine q KTCS, ARSC, and automatic suspension do not function.
q If failure code [DAQ0KK] or [DAQ2KK] is displayed, troubleshoot for that code first.
Related infor-
mation

Examine the battery voltage and specific gravity of the battery electrolyte.
Voltage Battery voltage Min. 24 V
1 Defective battery
Specific
gravity
Defective circuit breaker or The breaker between connectors 68 and 69 is opened, or fuse No. 2 of fuse BT4 is blown,
2
fuse the circuit may have a ground fault.

to OFF position.
Between ground and BRC3 (female) (21), (31), (32), (33)
Inspect for a loose or rusty ground terminal ER1.

2. Check that system operation lamp is not illuminated, then turn the battery disconnect
Open circuit in wiring har- switch to the OFF position.
3
ness 3. Disconnect the connector BRC3, and insert T-adapter into BRC3.
REMARK
Voltage appears between battery relay connector 76 and ground, but not between ground
and each connector BRC3 (1) and (11). The wiring harness may have an open circuit or
the fuse is blown.
Voltage
Between ground and BRC3 (1), (11) 20 to 30 V

switch to the OFF position.
3. Disconnect connectors BRC3, J01, fuse No. 1 to No. 15 in the fuse box BT2, fuse No.
4 11 to No. 15 in the fuse box BT4, and fuse No. 10 in the fuse box BT5.
ness
Between ground and BRC3 (1), (11) Min. 1 MΩ
Resistance
HD465-8, HD605-8 40-795


Defective retarder and
5 4. Turn battery disconnect switch ON.
hoist controller
Voltage Between ground and BRC3 (1), (11) 20 to 30 V
40-796 HD465-8, HD605-8

Circuit diagram related to main power supply to retarder and hoist controller
HD465-8, HD605-8 40-797

FAILURE CODE [DB19KQ] 40 TROUBLESHOOTING
FAILURE CODE [DB19KQ]

Action level Failure code Model Selection Signal Mismatch (RHC)
Failure
L03 DB19KQ (Retarder and hoist controller system)
Details of fail- Machine selection signals sent from the machine monitor when the start switch is turned to ON differ from the
ure machine settings kept in the retarder and hoist controller.
q Cancel controls of KTCS, ARSC, and the over run prevention retarder.
Effect of con- q Cancel automatic suspension control.
troller q Although the cause of failure is eliminated, the machine does not resume normal operation until the start
switch is turned to OFF.
Effect on the q KTCS, ARSC, and automatic suspension do not function.
q Perform initial setting and initial adjustment similar to those required when the retarder and hoist controller
Related infor- is replaced.

Incorrect machine type set- The machine type setting of the machine monitor is probably incorrect. After you replace
1 ting on the machine moni- the machine monitor or the retarder and hoist controller, set the machine type correctly.
tor For details, see TEST AND ADJUST, "DEFAULT MENU".
Installation of the incorrect
Installed incorrect retarder and hoist controller? Examine part No. and install the correct
2 retarder and hoist control-
retarder hoist controller.
ler
Defective retarder and If no failure is found by the previous checks, the retarder and hoist controller is defective.
3
hoist controller (Since this is an internal defect, you cannot troubleshoot.)
40-798 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DB1LKA]
FAILURE CODE [DB1LKA]

Action level Failure code System Operating Lamp Open Circuit (RHC)
Failure
- DB1LKA (Retarder and hoist controller system)
Retarder and hoist controller detected an open circuit because the output line voltage of the system operating
Details of fail-
lamp is 5 V or less during approximately 3 seconds when the retarder and hoist controller is not driven after
ure
the starting switch is turned to ON position.
q Turns the system operating lamp to OFF.
Effect of con-
troller
Effect on the
System operation lamp may not illuminate.
machine
q Do not turn the battery disconnect switch to "OFF" position while the system operation lamp is illuminated.
If the battery disconnect switch is set to OFF, the data kept in the retarder and hoist controller memory is
not stable.
q Although the retarder and hoist controller cannot light the system operating lamp, no trouble will occur
Related infor-
unless the battery disconnect switch is turned to OFF.
mation
q An open circuit can be detected because no controllers drive the system operating lamp for approximately
3 seconds after the starting switch is turned to ON position.

1 Defective fuse If fuse No. 14 in fuse case BT4 is broken, the circuit probably has ground fault.

2. While this failure code is shown, the condition of the system operating lamp is not
known. Turn the battery disconnect switch to OFF 3 minutes or later after you turn the
Open circuit in wiring har- start switch to OFF.
2
ness 3. Disconnect connectors BRC3 and OPL, and connect T-adapter to each female side.
Between BRC3 (female) (34) and OPL (female) (2) Max. 1 Ω
Resistance
Between OPL (female) (1) and battery relay terminal 76 Max. 1 Ω

Ground fault in wiring har- start switch to OFF.
3
ness 3. Remove the fuse No.14 in fuse box BT4.
4. Disconnect connector OPL, and connect T-adapter to the female side.
4
HD465-8, HD605-8 40-799

FAILURE CODE [DB1LKA] 40 TROUBLESHOOTING
40-800 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DB1LKA]
HD465-8, HD605-8 40-801

FAILURE CODE [DB1LKB] 40 TROUBLESHOOTING
FAILURE CODE [DB1LKB]

Action level Failure code System Operating Lamp Short Circuit (RHC)
Failure
- DB1LKB (Retarder and hoist controller system)
Details of fail- The retarder and hoist controller finds a short circuit. Because voltage of the output circuit does not become a
ure low level, although the retarder and hoist controller output current to the system operating lamp.
q Stops operation of the system operation lamp.
Effect of con-
troller
Effect on the
System operation lamp may not illuminate.
machine
q Do not turn the battery disconnect switch to "OFF" position while the system operation lamp is illuminated.
If the battery disconnect switch is set to OFF, the data kept in the retarder and hoist controller memory is
not stable.
q Although the retarder and hoist controller cannot light the system operating lamp, no trouble will occur
Related infor- unless the battery disconnect switch is turned to OFF.
mation q The voltage between pin (2) of the female side and ground becomes 20 V or above after you turn the start
switch to ON. Therefore, when connector OPL is open, you cannot examine for a hot short circuit in this
condition.

Hot short circuit in wiring start switch to OFF.
1
2
40-802 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DB1LKB]
HD465-8, HD605-8 40-803

FAILURE CODE [DB1LKB] 40 TROUBLESHOOTING
40-804 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DB1QKR]
FAILURE CODE [DB1QKR]

Action level Failure code CAN 2 Defective Communication (RHC)
Failure
L03 DB1QKR (Sensed by monitor controller) (Machine monitor system)
Details of fail- Monitor controller does not recognize the retarder and hoist controller on CAN 2 communication line (KOM-
ure NET/c).
Effect of con-
Does not update communication information with the retarder and hoist controller.
troller
q Failure codes related to the retarder and hoist controller are not shown.
Effect on the
q Data monitored related to the retarder and hoist controller are not up-dated.
machine
q Adjustment function (KTCS system check) not functional.
for the defective CAN communication by CAN 2. Those found by the monitor controller. When all 6 of these
failure codes are shown, ground fault, short circuit, or hot short circuit in wiring harness (CAN communication
line) are possible. The air conditioner is also operated through the CAN communication. Make sure the air con-
ditioner is operable (ON and OFF and the airflow adjusts) on the air conditioner screen.
mation Machine with ABS system also displays failure code [DBCQKR].
q If air conditioner is operable, wiring harness (CAN communication line) does not have ground fault, short
circuit, or hot short circuit.
q Each controller and the machine monitor (meter unit) are connected directly to the battery. They are sup-
plied with power, although the start switch is turned to OFF.

1 retarder and hoist control- Troubleshoot for failure code [DB13KK].
ler
cation line
3
4
HD465-8, HD605-8 40-805

FAILURE CODE [DB1QMA] 40 TROUBLESHOOTING
FAILURE CODE [DB1QMA]

Action level Failure code Option Selection Inconsistency (RHC)
Failure
L03 DB1QMA (Retarder and hoist controller system)
Details of fail- The start switch is turned to ON. The alternative equipment setting information sent from the machine monitor
ure differs from that kept in the retarder and hoist controller.
q Controls with the alternative equipment settings kept in the controller.
Effect of con-
q Although the failure is eliminated, the machine does not go back to normal until the start switch is turned
troller
to OFF.
Effect on the q ARSC may not operate although it is set.
machine q KTCS may not operate although it is set.

The alternative equipment setting of the machine monitor is probably incorrect. After you
replace the machine monitor or retarder and hoist controller, set the alternative equipment
Defective alternative equip- correctly. For details, see TEST AND ADJUST.
1 ment setting of the
machine monitor
REMARK
Perform initial setting and initial adjustment similar to those required when the retarder
and hoist controller is replaced.
2
40-806 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DB1RKR]
FAILURE CODE [DB1RKR]

Action level Failure code CAN 1 Defective Communication (RHC)
Failure
L03 DB1RKR (Found by monitor controller) (Machine monitor system)
Details of fail- Monitor controller does not recognize the retarder and hoist controller on the CAN1 communication line
ure (KOMNET/r).
Effect of con-
Hides indication of the retarder oil temperature gauge from screen.
troller
q Information from the retarder and hoist controller is not shown, special functions are not done, or received
Effect on the
data is no longer up-to-date.
machine
q Retarder oil temperature is not shown.
q Other failure codes of the defective CAN communication through CAN1, found by the monitor controller are
[DAQRKR], [DB2RKR], and [DBVRKR]. Failure codes [DAQRKR], [DB2RKR] and [DBVRKR] are also shown.
Then, ground fault, short circuit or hot short circuit in wiring harness (CAN communication line) is suspect.
REMARK
Related infor- Machine with ABS system also displays failure code [DBCRKR].
mation q CAN1 terminating resistors are located in the monitor controller on operator's side of the cab. Connector
“KOM/cRES1” is located on the engine side.
q Each controller and the monitor controller are connected directly to the battery. They remain supplied with
power after start switch is turned to OFF.
Procedure turn the start switch to the ON position.

1 retarder and hoist control- Troubleshoot for failure code [DB13KK].
ler
cation line
3
4
HD465-8, HD605-8 40-807

FAILURE CODE [DB2QKR] 40 TROUBLESHOOTING

Action level Failure code CAN 2 Defective Communication (Engine Controller)
Failure
L03 DB2QKR (Found by monitor controller) (Machine monitor system)
Details of fail-
Monitor controller does not recognize the engine controller on CAN 2 communication line (KOMNET/c).
ure
Effect of con-
Does not update communication information with the engine controller.
troller
q Failure codes related to the engine controller are not shown.
Effect on the q Monitored data related to the engine controller is not up-dated.
machine q KDPF manual regeneration is not available.
q Cylinder cutout mode and no-injection cranking are not available.
for defective CAN communication by CAN 2 detected by the monitor controller. When all 6 of these failure codes
are shown, ground fault, short circuit, or hot short circuit in wiring harness (CAN communication line) are pos-
sible. The air conditioner is also operated through the CAN communication. Make sure the air conditioner is
Related infor- operable (ON and OFF and the airflow adjusts) on the air conditioner screen.
mation q If the air conditioner is operable, wiring harness (CAN communication line) does not have a ground fault,
short circuit, or hot short circuit.

2. Remove the fuse No. 9 and No. 12 in fuse box BT3.
1 Defective fuse q If fuse No. 9 in fuse case BT3 is broken, there is probably a short circuit in the engine
controller.
q If fuse No. 12 in fuse case BT3 is broken, the circuit probably has ground fault.
If the fuse is not broken, the next check is not required.
2. Remove connectors ECM1 J2 and ECM2 J2, and connect T-adapter to the male side.
Between ECM1 J2, ECM2 J2 (male) (1) and (49) Max. 1 Ω
Resistance
Make sure ground connector ER10 is not loose and has no rust.
2. Remove connectors ECM1 J2 and ECM2 J2, and connect T-adapter to the female
side.
4. If any problem is found, troubleshoot for failure code [CA441]
Between ECM1 J2, ECM2 J2 (female) (1) and (49) 20 to 30 V
Voltage

2. Disconnect connectors DPC3 and KOM/c_RES1, and connect T-adapter to each male
Defective CAN terminating side.
4
resistor
Between KOM/c_RES1 (male) (A) and (B) 120±12 Ω
Resistance
Between DPC3 (male) (7) and (8) 120±12 Ω
40-808 HD465-8, HD605-8


CAN communication line
REMARK
q CAN terminating resistor of 120 Ω is also located in the machine monitor. Two CAN
terminating resistors of 120 Ω are connected in parallel. Together, resistance is 60 Ω,
when circuit resistance is measured at the connector of the controller (other than ma-
chine monitor). The wiring harness does not have an open circuit.
2. Check that system operation lamp is not illuminated, then turn the battery discon-
3. Disconnect the related connector, and connect T-adapter to the connector to be
measured.
q A short circuit occurs (when resistance between the connectors is 1Ω or less). Exam-
ine whether the short circuit occurs between the wiring harnesses or in the controller.
Disconnect all the CAN communication connectors of each controller to measure.
Open or short circuit in wir-
5
ing harness Approx. 120
Between DPC3 (female) (3) and (8)
Ω
Between ECM1 J2, ECM2 J2 (female) (22) and (46) Approx. 60 Ω
Between MCM2 (female) (97) and (89) Approx. 60 Ω
Between BRC2 (female) (32) and (22) Approx. 60 Ω
Resistance Between ATC2 (female) (32) and (22) Approx. 60 Ω
Between AC1 (female) (9) and (10) Approx. 60 Ω
Between KOM1A (female) (10) and (11) Approx. 60 Ω
Between KPS2 (female) (41) and (42) Approx. 60 Ω
Approx. 120
Between KOM/c_RES1 (female) (A) and (B)
Ω
HD465-8, HD605-8 40-809


Start switch of the ACC signal (start of CAN communication is not recognized.)
3. Disconnect the connector to be measured, and insert T-adapter.
4. Turn the battery disconnect switch to the ON position, and then turn the start switch to
the on position.
Between ECM1 J2 (5) and (49) 20 to 30 V
Between MCM1 (24) and (2) 20 to 30 V
Between DPC3 (2) and (4) 20 to 30 V
Voltage Between BRC3 (14), (24) and (21) 20 to 30 V
Between ATC3 (14), (24) and (21) 20 to 30 V
Between AC2 (4) and (1) 20 to 30 V
Between KOM2 (4) (5) and (6) 20 to 30 V
If there is no failure found by the check on cause 5, the next check is not required.
3. Disconnect the related connector, and connect T-adapter to each female side
connector to be measured.
Open circuit in wiring har- Between DPC3 (female) (3) and MCM2 (female) (97) Max. 1 Ω
6
ness Between DPC3 (female) (8) and MCM2 (female) (89) Max. 1 Ω
Between MCM2 (female) (97) and ATC2 (female) (32) Max. 1 Ω
Between MCM2 (female) (97) and ECM1 J2, ECM2 J2
Max. 1 Ω
(female) (22)
Max. 1 Ω
(female) (46)
Between MCM2 (female) (97) and BRC2 (female) (32) Max. 1 Ω
Resistance
Between MCM2 (female) (97) and AC1 (female) (9) Max. 1 Ω
Between MCM2 (female) (97) and KOM1A (female) (10) Max. 1 Ω
Between ECM1 J2, ECM2 J2 (female) (22) and
Max. 1 Ω
KOM/c_RES1 (female) (A)
Max. 1 Ω
KOM/c_RES1 (female) (B)
Between MCM2 (female) (97) and KPS2 (female) (42) Max. 1 Ω
40-810 HD465-8, HD605-8


If no failure (no open circuit) is found with the check on cause 5, measure the resistance
at any one of the points.
3. Disconnect the related connector, and connect a T-adapter to the female side
7 Between ground and DPC3 (female) (3), ATC2 (female)
ness
(32), KOMIA (female) (10), AC1 (female) (9), ECM1 J2,
Min. 1 MΩ
ECM2 J2 (female) (22), BRC2 (female) (32), MCM2
(female) (97), or KPS2 (female) (42)
Resistance
Between ground and DPC3 (female) (8), ATC2 (female)
(22), KOMIA (female) (11), AC1 (female) (10), ECM1 J2,
Min. 1 MΩ
If no open circuit is found with the check on cause 5, measure the resistance at any one
point for each of the resistance cases.
3. Disconnect the connector to be measured, and connect T-adapter to the connector.
4. Turn the battery disconnect switch to the "ON" position.
Short circuit or hot short REMARK

8
circuit in wiring harness q ECM1 J1, ECM2 J1, and MCM2 are not required to measure resistance.
q Voltage of CAN H and CAN L is 2.5 ± 1.0 V including that communication, therefore
regard wiring harness as normal when measured voltage is 1 to 4 V.
(32), KOMIA (female) (10), AC1 (female) (9), BRC2 1 to 4 V
Voltage
(22), KOMIA (female) (11), AC1 (female) (10), BRC2 1 to 4 V
When all 6 of these failure codes [DBVQKR], [DB1QKR], [DB2QKR], [DAQQKR],
[DAZQKR], and [DSJ0KR] are shown:
REMARK
To identify the defective controller, repeat steps 1 thru 3 to disconnect controllers one by
one from the CAN communication line.
Defective engine controller, 1. Turn the start switch to the OFF position.
retarder and hoist control- 2. Check that system operation lamp is not illuminated, then turn the battery disconnect
ler, transmission control- switch to the OFF position.
ler, air conditioner 3. Disconnect each CAN communication connector of the engine controller (connector
9
controller, machine monitor ECM1 J2 and ECM2 J2), the retarder and hoist controller (connector BRC2), the trans-
(meter unit), KOMTRAX mission controller (connector ATC2), air conditioner controller (connector ATC1), the
terminal, and KOMTRAX machine monitor (DPC3), KOMTRAX terminal (connector KOMIA), and KOMTRAX
Plus terminal plus terminal (KPS2) one by one in order.
4. Turn the battery disconnect switch to ON, and then turn the start switch to ON to
measure.
5. Back to step 1, and examine next controller.
Has the number of shown failure codes If YES, the disconnected controller is defec-
decreased from 6? tive.
HD465-8, HD605-8 40-811


11
Circuit diagram related to CAN 2 communication
40-812 HD465-8, HD605-8

Circuit diagram related to the engine controller
HD465-8, HD605-8 40-813


Action level Failure code CAN 2 Defective Communication (Engine Controller) (Machine with ABS
Failure system)
L03 DB2QKR (Detected by monitor controller) (Machine monitor system)
Details of fail-
Monitor controller does not recognize the engine controller on CAN 2 communication line (KOMNET/c).
ure
Effect of con-
Does not update communication information with the engine controller.
troller
q Failure codes related to the engine controller are not shown.
Effect on the q Monitored data related to the engine controller is not up-dated.
machine q KDPF manual regeneration is not available.
q Cylinder cutout mode and no-injection cranking are not available.
q 7 different failure codes, [D8VQKR], [DAQQKR], [DB1QKR], [DB2QKR], [DAZQKR], [DSJ0KR], and [DB-
CQKR] are used for defective CAN communication by CAN2 detected by the monitor controller. When all
of these 7 failure codes are displayed, ground fault, short circuit, or hot short circuit in wiring harness (CAN
communication line) can be suspected. In such case, since the air conditioner is also operated through
CAN communication, check whether the air conditioner is operable (ON/OFF and the air flow adjustment)
Related infor-
on the air conditioner screen.
mation
q If the air conditioner is operable, wiring harness (CAN communication line) does not have a ground fault,

2. Remove the fuse No. 9 and No. 12 in fuse box BT3.
1 Defective fuse q If fuse No. 9 in fuse case BT3 is broken, there is probably a short circuit in the engine
controller.
q If fuse No. 12 in fuse case BT3 is broken, the circuit probably has ground fault.
If the fuse is not broken, the next check is not required.
2. Remove connectors ECM1 J2 and ECM2 J2, and connect T-adapter to the male side.
Resistance
Make sure ground connector ER10 is not loose and has no rust.
2. Remove connectors ECM1 J2 and ECM2 J2, and connect T-adapter to the female
side.
4. If any problem is found, troubleshoot for failure code [CA441]
Voltage

2. Disconnect connectors DPC3 and KOM/c_RES1, and connect T-adapter to each male
4
resistor
Between KOM/c_RES1 (male) (A) and (B) 120±12 Ω
Resistance
Between DPC3 (male) (7) and (8) 120±12 Ω
40-814 HD465-8, HD605-8


REMARK
q CAN terminating resistor of 120 Ω is also located in the machine monitor. Two CAN
terminating resistors of 120 Ω are connected in parallel. Together, resistance is 60 Ω,
when circuit resistance is measured at the connector of the controller (other than ma-
chine monitor). The wiring harness does not have an open circuit.
3. Disconnect the related connector, and connect T-adapter to the connector to be
measured.
q A short circuit occurs (when resistance between the connectors is 1Ω or less). Exam-
ine whether the short circuit occurs between the wiring harnesses or in the controller.
Disconnect all the CAN communication connectors of each controller to measure.
Open or short circuit in wir- Approx. 120
5 Between DPC3 (female) (3) and (8)
ing harness Ω
Between ECM1 J2, ECM2 J2 (female) (22) and (46) Approx. 60 Ω
Between MCM2 (female) (97) and (89) Approx. 60 Ω
Between ATC2 (female) (32) and (22) Approx. 60 Ω
Resistance
Between AC1 (female) (9) and (10) Approx. 60 Ω
Between KOM1A (female) (10) and (11) Approx. 60 Ω
Approx. 120
Between KOM/c_RES1 (female) (A) and (B)
Ω
Between OPC2 (female) (32) and (22) Approx. 60 Ω
HD465-8, HD605-8 40-815


4. Turn the battery disconnect switch to ON position, and then turn the starting switch to
ON position.
Between ECM1 J2 (5) and (49) 20 to 30 V
Between MCM1 (24) and (2) 20 to 30 V
Between DPC3 (2) and (4) 20 to 30 V
Between BRC3 (14), (24) and (21) 20 to 30 V
Voltage
Between AC2 (4) and (1) 20 to 30 V
Between KOM2 (4) (5) and (6) 20 to 30 V
Between OPC3 (14), (24) and (21) 20 to 30 V
If there is no failure found by the check on cause 5, the next check is not required.
3. Disconnect the related connector, and connect T-adapter to each female side
Between DPC3 (female) (3) and MCM2 (female) (97) Max. 1 Ω
Open circuit in wiring har- Between DPC3 (female) (8) and MCM2 (female) (89) Max. 1 Ω
6
ness
Max. 1 Ω
(female) (22)
Max. 1 Ω
(female) (46)
Resistance
Max. 1 Ω
KOM/c_RES1 (female) (A)
Max. 1 Ω
KOM/c_RES1 (female) (B)
Between MCM2 (female) (97) and OPC2 (female) (32) Max. 1 Ω
40-816 HD465-8, HD605-8


If no failure (no open circuit) is found with the check on cause 5, measure the resistance
at any one of the points.
3. Disconnect the related connector, and connect a T-adapter to the female side
7 Between ground and DPC3 (female) (3), ATC2 (female)
ness
(32), KOM1A (female) (10), AC1 (female) (9), ECM1 J2,
Min. 1 MΩ
(female) (97), KPS2 (female) (42), or OPC2 (female) (32)
Resistance
(22), KOM1A (female) (11), AC1 (female) (10), ECM1 J2,
Min. 1 MΩ
3. Disconnect the connector to be measured, and connect T-adapter to the connector.

8
circuit in wiring harness q ECM1 J1, ECM2 J1, and MCM2 are not required to measure resistance.
(32), KOM1A (female) (10), AC1 (female) (9), BRC2 1 to 4 V
Voltage
(22), KOM1A (female) (11), AC1 (female) (10), BRC2 1 to 4 V
When all of these 6 failure codes [DBVQKR], [DB1QKR], [DB2QKR], [DAQQKR],
[DAZQKR], and [DSJ0KR] are displayed:
REMARK
To identify the defective controller, repeat steps 1 thru 3 to disconnect controllers one by
one from the CAN communication line.
Defective engine controller, 1. Turn the start switch to the OFF position.
retarder and hoist control- 2. Check that system operation lamp is not illuminated, then turn the battery disconnect
ler, transmission control- switch to the OFF position.
ler, air conditioner 3. Disconnect each CAN communication connector of the engine controller (connector
9 controller, machine monitor ECM1 J2 and ECM2 J2), the retarder and hoist controller (connector BRC2), the trans-
(meter unit), KOMTRAX mission controller (connector ATC2), the air conditioner controller (connector AC1),
terminal, KOMTRAX Plus the machine monitor (DPC3), the KOMTRAX terminal (connector KOM1A), the
terminal, and ABS control- KOMTRAX plus terminal (KPS2), and the ABS controller (connector OPC2) one by
ler one in order.
ON position to check.
Has the number of displayed failure codes If YES, the disconnected controller is defec-
HD465-8, HD605-8 40-817


11
Circuit diagram related to CAN 2 communication
40-818 HD465-8, HD605-8

Circuit diagram related to the engine controller
HD465-8, HD605-8 40-819

Circuit diagram related to ABS controller
40-820 HD465-8, HD605-8


Action level Failure code CAN 1 Defective Communication (Engine Controller)
Failure
L03 DB2RKR (Found by monitor controller) (Machine monitor system)
Details of fail-
Monitor controller does not recognize the engine controller on the CAN1 communication line (KOMNET/r).
ure
Effect of con- q Hides indication of the engine coolant temperature gauge on the screen.
troller q Sets indication of the engine speed meter to zero point.
q Information to be obtained from the engine controller and special functions are not shown, and they do
not work, or received data is not up-dated.
Effect on the
q Engine control is disabled.
machine
q Engine coolant temperature is not found.
q Engine speed is shown at 0 rpm.
q Other failure codes of the defective CAN communication through CAN1, detected by the monitor control-
ler are [DAQRKR], [DB1RKR], and [DBVRKR]. When the failure codes [DAQRKR], [DB1RKR] and [DB-
VRKR] are also displayed, ground fault, short circuit or hot short circuit in wiring harness (CAN
Related infor- communication line) can be suspected.
mation q CAN1 terminating resistors are located in the monitor controller on operator's cab side.
q Since each controller is connected directly to the battery, it is supplied with power after the start switch is
turned to OFF.
Procedure: turn the start switch to the ON position.

Defective engine controller
system

2. Disconnect connectors MCM2 and KOM/r_RES, and connect T-adapter to each male
2
resistor
Between KOM/r_RES (male) (A) and (B) 120 ±12 Ω
Resistance
Between MCM2 (male) (105) and (112) 120±12 Ω
HD465-8, HD605-8 40-821

FAILURE CODE [DB2RKR] 40 TROUBLESHOOTING

REMARK
q CAN terminating resistor of 120 Ω is also located in the monitor controller Two CAN
terminating resistors of 120 Ω are connected in parallel. Circuit resistance is measured
at controller connector other than machine monitor, and total resistance is 60 Ω, wiring
harness does not have open circuit.
3. Disconnect connectors MCM2, ATC2, BRC2, ECM1 J1, KOM/r_RES, and KOM/r
one by one, and connect a T-adapter to the female side.
Open or short circuit in wir- q A short circuit occurs (resistance between the connectors is 1Ω or less). Check wheth-
3 er the short circuit occurs between the wiring harnesses or in the controller. Discon-
ing harness
nect all the CAN communication connectors and examine each controller.
Approx. 120
Between MCM2 (female) (113) and (105)
Ω
Resistance
Approx. 120
Between KOM/r_RES, KOM/r (female) (A) and (B)
Ω
Between ECM1 J1 (female) (70) and (94) Approx. 60 Ω
40-822 HD465-8, HD605-8


ON position.
Between MCM1 (24), (43) and (3) 20 to 30 V
Between J2 (5) and (49) 20 to 30 V
Voltage
Between BRC3 (14), (24) and (21) 20 to 30 V
If there is no failure by the check on cause 3, the next check is not required.
Open circuit in wiring har- 3. Disconnect the related connector, and connect T-adapter to each female side to be
4
ness measured.
Between MCM2 (female) (113) and ECM1 J1 (female) (70) Max. 1 Ω
Resistance Between MCM2 (female) (105) and ECM1 J1 (female) (94) Max. 1 Ω
Between ECM J1 (female) (70) and KOM/r_RES, KOM/r
Max. 1 Ω
(female) (A)
Max. 1 Ω
(female) (B)

3. Disconnect connectors MCM2, BRC2, ATC2, ECM1 J1, KPS2, and KOM/r_RES, and
connect T-adapter to either female side.
Between ground and BRC2 (female) (33), ATC2 (female)
Ground fault in wiring har- (33), MCM2 (female) (113), (112), or ECM1 J1 (female)
5
ness (70) Min. 1 MΩ
Resistance (female) (A), or KPS2 (female) (32)
(23), MCM2 (female) (105), or ECM1 J1 (female) (94)
Min. 1 MΩ
Between ground and ECM J1 (female) (94), KOM/r_RES,
KOM/r (female) (B), or KPS2 (female) (31)
HD465-8, HD605-8 40-823


3. Disconnect connector either BRC2, ATC2, or KOM/r_RES, and connect T-adapter to
the female side.
Short circuit or hot short 5. Turn the start switch to the ON position.
6
circuit in wiring harness REMARK
q ECM1 J1 and MCM2 are not required to measure resistance.
1 to 4 V
(33), KPS2 (female) (32), or KOM/r_RES (female) (A)
Voltage
1 to 4 V
(23), KPS2 (female) (31), or KOM/r_RES (female) (B)
When all of these 4 failure codes [DAQRKR], [DB1RKR], [DB2RKR], and [DBVRKR] are
displayed:
REMARK
To identify the defective controller, repeat the following steps 1 to 3 to disconnect control-
lers one by one from CAN communication line.
controller, retarder and
7 hoist controller, engine
controller, and KOMTRAX 3. Disconnect each CAN communication connector of the engine controller (connector
Plus controller ECM1 J1), the retarder and hoist controller (connector BRC2), the transmission
controller (connector ATC2), and the machine monitor (MCM2) one by one in order.
4. Turn the battery disconnect switch to ON and then turn the start switch to ON to make
sure.
Has the number of the shown failure codes If YES, the disconnected controller is defec-
9
40-824 HD465-8, HD605-8

Circuit diagram related to CAN1 communication
HD465-8, HD605-8 40-825

Circuit diagram related to engine controller
40-826 HD465-8, HD605-8


Action level Failure code CAN 1 Defective Communication (Engine Controller) (Machine with ABS
Failure system)
L03 DB2RKR (Detected by monitor controller) (Machine monitor system)
Details of fail-
Monitor controller does not recognize the engine controller on the CAN1 communication line (KOMNET/r).
ure
Effect of con- q Hides indication of the engine coolant temperature gauge on the screen.
troller q Sets indication of the engine speed meter to zero point.
q Information to be obtained from the engine controller and special functions are not displayed, and they do
not work, or received data is not updated.
Effect on the
q Engine control is disabled.
machine
q Engine coolant temperature is not found.
q Engine speed is shown at 0 rpm.
ler are [DAQRKR], [DB1RKR], [DBVRKR], and [DBCRKR]. When the failure codes [DAQRKR],
[DB1RKR], [DBVRKR], and [DBCRKR] are also displayed, ground fault, short circuit or hot short circuit in
Related infor- wiring harness (CAN communication line) can be suspected.
turned to OFF.
Procedure: turn the start switch to the ON position.

Defective engine controller
system

2. Disconnect connectors MCM2 and KOM/r_RES, and connect T-adapter to each male
2
resistor
Between KOM/r_RES (male) (A) and (B) 120 ±12 Ω
Resistance
Between MCM2 (male) (105) and (112) 120±12 Ω
HD465-8, HD605-8 40-827


REMARK
q CAN terminating resistor of 120 Ω is also located in the monitor controller Two CAN
terminating resistors of 120 Ω are connected in parallel. Circuit resistance is measured
at controller connector other than machine monitor, and total resistance is 60 Ω, wiring
harness does not have open circuit.
3. Disconnect connectors MCM2, ATC2, BRC2, ECM1 J1, KOM/r_RES, KOM/r, and
OPC2 one by one, and connect T-adapter to female side.
q If a short circuit occurs (when resistance between the terminals is 1Ω or less), check
Open or short circuit in wir- whether the short circuit occurs between the wiring harnesses or inside the controller
3
ing harness by disconnecting all the CAN communication connectors of each controller.
Approx. 120
Between MCM2 (female) (113) and (105)
Ω
Resistance Approx. 120
Between KOM/r_RES, KOM/r (female) (A) and (B)
Ω
Between ECM1 J1 (female) (70) and (94) Approx. 60 Ω
Between OPC2 (female) (33) and (23) Approx. 60 Ω
40-828 HD465-8, HD605-8


ON position.
Between MCM1 (24), (43) and (3) 20 to 30 V
Between J2 (5) and (49) 20 to 30 V
Voltage Between BRC3 (14), (24) and (21) 20 to 30 V
Between OPC2 (14), (24) and (21) 20 to 30 V
If there is no failure by the check on cause 3, the next check is not required.
Open circuit in wiring har- 3. Disconnect the related connector, and connect T-adapter to each female side to be
4 measured.
ness
Resistance Between ECM J1 (female) (70) and KOM/r_RES, KOM/r

Max. 1 Ω
(female) (A)
Max. 1 Ω
(female) (B)

3. Disconnect connectors MCM2, BRC2, ATC2, ECM1 J1, KPS2, and KOM/r_RES, and
(33), MCM2 (female) (113), (112), or ECM1 J1 (female)
Ground fault in wiring har- (70)
5 Min. 1 MΩ
ness Between ground and ECM1 J1 (female) (70) and
KOM/r_RES, KOM/r (female) (A), KPS2 (female) (32), or
Resistance OPC2 (female) (33)
(23), MCM2 (female) (105), or ECM1 J1 (female) (94)
Between ground and ECM1 J1 (female) (94) and Min. 1 MΩ
KOM/r_RES, KOM/r (female) (B), KPS2 (female) (31), or
OPC2 (female) (23)
HD465-8, HD605-8 40-829


3. Disconnect connector either BRC2, ATC2, or KOM/r_RES, and connect T-adapter to
the female side.
6
circuit in wiring harness
q ECM1 J1 and MCM2 are not required to measure resistance.
(33), KPS2 (female) (32), KOM/r_RES (female) (A), or 1 to 4 V
OPC2 (female) (33)
Voltage
(23), KPS2 (female) (31), KOM/r_RES (female) (A), or 1 to 4 V
OPC2 (female) (23)
When all of these 5 failure codes [DAQRKR], [DB1RKR], [DB2RKR], [DBVRKR], and
[DBCRKR] are displayed:
REMARK
To identify the defective controller, repeat the following steps 1 to 3 to disconnect control-
lers one by one from CAN communication line.
controller, retarder and
hoist controller, engine
7 3. Disconnect each CAN communication connector of the engine controller (connector
controller, KOMTRAX Plus
terminal, and ABS control- ECM1 J1), the retarder and hoist controller (connector BRC2), the transmission
ler controller (connector ATC2), the machine monitor (MCM2), and the ABS controller
(connector OPC2) one by one in order.
ON position to check.
Has the number of displayed failure codes If YES, the disconnected controller is defec-
9
40-830 HD465-8, HD605-8

Circuit diagram related to CAN1 communication
HD465-8, HD605-8 40-831

Circuit diagram related to engine controller
40-832 HD465-8, HD605-8

Circuit diagram related to ABS controller
HD465-8, HD605-8 40-833

FAILURE CODE [DBC0KT] 40 TROUBLESHOOTING
FAILURE CODE [DBC0KT]

Action level Failure code Non-volatile Memory (ABS Controller) Abnormality
Failure
L01 DBC0KT (ABS controller system)
Details of fail-
Non-volatile memory in the controller is abnormal.
ure
q Controls the machine using already set values of the machine type selection with additions and their set-
Effect of con- tings.
troller q Even if the cause of failure is eliminated, the machine does not return to normal until the starting switch
is turned to OFF position.
Effect on the
ABS may not be operating.
machine

ABS controller is defective. (Since this is an internal defect, troubleshooting cannot be
1 Defective ABS controller
performed.)
40-834 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DBC0MC]
FAILURE CODE [DBC0MC]

Action level Failure code ABS Controller Error
Failure
- DBC0MC (ABS controller system)
Details of fail-
Controller shows abnormal control (unexpected control).
ure
Effect of con-
Set controller CPU again, and then start it again.
troller
Event on q Machine returns to same initial condition as that when starting switch is turned to ON position.
machine q System does not operate properly.

ABS controller is defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
HD465-8, HD605-8 40-835

FAILURE CODE [DBC1KA] 40 TROUBLESHOOTING
FAILURE CODE [DBC1KA]

Action level Failure code Key Switch ACC terminal (ABS Controller) Disconnection
Failure
L03 DBC1KA (ABS controller system)
Details of fail-
Key switch signal is OFF on the ABS controller, while that on the retarder and hoist controller is ON.
ure
Effect of con-
Cancels ABS control.
troller
Effect on the q ABS does not work.
machine q Front brake cut does not function and the front brake works.

2. Disconnect connectors OPC3 and ESS, and connect T-adapter to each female side.
1
ness Between OPC3 (female) (14) and ESS (female) (4) Max. 1 Ω
Resistance
Between OPC3 (female) (24) and ESS (female) (4) Max. 1 Ω

2. Insert T-adapter into connector OPC3.
Voltage Between OPC3 (14), (24) and (21), (31), (32), (33) 20 to 30 V
If no failure is found by the above checks, the ABS controller is defective. (Since this is an
internal defect, troubleshooting cannot be performed.)
40-836 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DBC1KA]
Circuit diagram related to ABS controller key switch ACC signal
HD465-8, HD605-8 40-837

FAILURE CODE [DBC1KA] 40 TROUBLESHOOTING
Circuit diagram related to ABS controller key switch ACC signal (For machines equipped with emergency engine
stop switch)
40-838 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DBC2KK]
FAILURE CODE [DBC2KK]

Action level Failure code Drop in Anti-skid Brake System Controller Solenoid Power Source
Failure
L03 DBC2KK (ABS controller system)
Details of fail-
Solenoid power supply voltage is 18 V or below, while the controller direct power supply voltage is normal.
ure
Effect of con-
troller
q If failure code [DAQ0KK] and/or [DAQ2KK] (transmission controller power supply) is displayed, perform
Related infor- troubleshooting for it first.

Defective circuit breaker or The circuit breaker between connectors 64 and 65, or the fuse No. 2 of the fuse BT4 is
1
fuse blown. The circuit may have a ground fault.

to OFF position.
3. Disconnect connector OPC3, and connect T-adapter to female side.
REMARK
When the voltage of battery relay terminal 77 is normal and the voltages of connectors
OPC3 (2), (12), and (22) are abnormal, there is an open circuit in wiring harness between
Open circuit in wiring har- battery relay terminal 77 and each of connectors OPC3 (female) (2), (12), and (22).
2
ness Between battery relay terminal 77 and ground 20 to 30 V
Voltage Between ground and OPC3 (female) (2), (12), (22)
20 to 30 V

to OFF position.
Between ground and OPC3 (female) (21), (31), (32), (33)

3. Remove the fuse No. 2 to No. 10 in the fuse box BT4, and fuse No. 1 to No. 4 in the
Ground fault in wiring har- fuse box BT5.
3
ness 4. Disconnect connectors OPC3, J04, and J13, and connect T-adapter to female side of
OPC3.
Between ground and OPC3 (female) (2), (12), (22) Min. 1 MΩ
Resistance
HD465-8, HD605-8 40-839

FAILURE CODE [DBC2KK] 40 TROUBLESHOOTING

to OFF position.
Voltage Between ground and OPC3 (2), (12), (22) 20 to 30 V
Circuit diagram related to solenoid power supply
40-840 HD465-8, HD605-8

FAILURE CODE [DBC3KK]

Action level Failure code Drop in ABS Controller Battery Direct Power Source
Failure
L03 DBC3KK (ABS controller system)
Details of fail- Direct power supply voltage drops to 18 V or lower. Other than when the engine is turned with the start switch
ure at ON or when the secondary steering is in operation.
Effect of con-
troller

Defective controller power
1 If failure code [DAQ0KK] or [DAQ2KK] is displayed, perform troubleshooting for it first.
supply
Examine the battery voltage and specific gravity of the battery electrolyte.
Voltage Battery voltage Min. 24 V
2 Defective battery
Specific
gravity
Defective circuit breaker or If the circuit breaker between terminals 68 and 69 is tripped, or the fuse No. 7 of the fuse
3
fuse BT4 is blown out, the circuit may have ground fault.

to OFF position.
Between ground and OPC3 (female) (21), (31), (32), (33)

Open circuit in wiring har- 3. Disconnect connector OPC3, and connect T-adapter to female side.
4
ness
REMARK
If voltage is normal on battery relay terminal 76, but not present between ground and each
of connector OPC3 (1) and (11), the wiring harness may have open circuit or the fuse may
be blown out.
Voltage Between ground and OPC3 (female) (2), (12), (22)
20 to 30 V

3. Disconnect connectors OPC3, J01, fuse No. 1 to No. 15 in the fuse box BT2, fuse No.
5 11 to No. 15 in the fuse box BT4, and fuse No. 10 in the fuse box BT5.
ness
Between OPC3 (female) (1), (11) and ground Min. 1 MΩ
Resistance
HD465-8, HD605-8 40-841

FAILURE CODE [DBC3KK] 40 TROUBLESHOOTING

to OFF position.
6 Defective ABS controller 4. Turn the battery disconnect switch to ON position.
Voltage Between ground and OPC3 (1), (11) 20 to 30 V
40-842 HD465-8, HD605-8

Circuit diagram related to main power supply to ABS controller
HD465-8, HD605-8 40-843

FAILURE CODE [DBC9KQ] 40 TROUBLESHOOTING
FAILURE CODE [DBC9KQ]

Action level Failure code Model Selection (ABS Controller) Inconsistency
Failure
L03 DBC9KQ (ABS controller system)
Details of fail- Model selection signals sent from the machine monitor when the starting switch is turned to ON position differ
ure from the model information stored in the ABS controller.
q Cancels ABS control.
Effect of con-
q Even if the cause of failure is eliminated, the machine does not return to normal until the starting switch
troller
q Perform initial setting and initial adjustment similar to those required when the ABS controller is replaced.
Related infor-
mation

The machine model setting of the machine monitor is probably incorrect. After replacing
Defective model setting on
1 the machine monitor or the ABS controller, set the model correctly. For details, see TEST
machine monitor
AND ADJUST, "DEFAULT MENU".
Installation of incorrect Incorrect ABS controller may be installed. Check part No. and install correct retarder and
2
ABS controller hoist controller.
40-844 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DBCLKA]
FAILURE CODE [DBCLKA]

Action level Failure code System Operating Lamp (ABS Controller) Disconnection
Failure
- DBCLKA (ABS controller system)
ABS controller detected an open circuit, because the output line voltage of the system operating lamp is 5 V
Details of fail-
or lower during approximately 3 seconds when the ABS controller is not driven after starting switch is turned
ure
to ON position.
q Stops driving system operating lamp.
Effect of con-
troller
Effect on the
System operating lamp may not light up while the controller is performing end processing
machine
q Although the ABS controller cannot turn on the system operating lamp, no trouble will result unless battery
disconnect switch is turned to OFF position within 3 minutes after the starting switch is turned to OFF po-
sition.
Related infor- q Do not turn the battery disconnect switch to OFF position while the system operating lamp is lit.
mation q An open circuit can be detected because no controllers drive the system operating lamp for approximately
3 seconds after the starting switch is turned to ON position.

start switch to OFF.
1 Defective fuse 3. Remove fuse No. 14 in fuse box BT4, and visually check if it is blown out.
4. If the fuse is not blown out, perform a continuity test to check if it is broken.
q If the fuse is not blown out but has no continuity, replace the fuse.

ness
4. Disconnect connectors OPC3, and OPL, and connect T-adapter to each female side.
Resistance
Between OPC3 (female) (34) and OPL (female) (2) Max. 1 Ω

3
HD465-8, HD605-8 40-845

FAILURE CODE [DBCLKA] 40 TROUBLESHOOTING
40-846 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DBCLKB]
FAILURE CODE [DBCLKB]

Action level Failure code System Operating Lamp (ABS Controller) Short Circuit
Failure
- DBCLKB (ABS controller system)
Details of fail- ABS controller detected a short circuit because the output voltage does not decrease below the specified volt-
ure age when the ABS controller drives the system operating lamp.
q Stops operation of the system operation lamp.
Effect of con-
troller
q When the controller drives the system operating lamp, large current flows through the circuit and may blow
Effect on the
out the controller.
machine
q System operating lamp may not light up while the controller is performing end processing
Although the ABS controller cannot turn on the system operating lamp, no trouble will result unless battery
disconnect switch is turned to OFF position within 3 minutes after the starting switch is turned to OFF position.
Related infor-
mation
REMARK
Since the voltage between pin (2) of female side and ground becomes 20 V or above after turning starting
switch to ON position when connector OPL is open, the check of hot short circuit cannot be performed.

1
HD465-8, HD605-8 40-847

FAILURE CODE [DBCLKB] 40 TROUBLESHOOTING
40-848 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DBCQKR]
FAILURE CODE [DBCQKR]

Action level Failure code CAN2 Defective Communication (ABS Controller)
Failure
L03 DBCQKR (Detected by monitor controller) (Machine monitor system)
Details of fail- Monitor controller does not obtain information from the ABS controller on CAN2 communication line (KOM-
ure NET/c).
Effect of con-
Does not update communication information with the ABS controller.
troller
q Failure codes related to the ABS controller are not displayed.
Effect on the
q Monitoring data related to the ABS controller is not updated.
machine
q ABS may not be operating normally.
q 7 different failure codes, [D8VQKR], [DAQQKR], [DB1QKR], [DB2QKR], [DAZQKR], [DSJ0KR], and [DB-
CQKR] are used for defective CAN communication by CAN2 detected by the monitor controller. When all
of these 7 failure codes are displayed, ground fault, short circuit, or hot short circuit in wiring harness (CAN
communication line) can be suspected. In such case, since the air conditioner is also operated through
CAN communication, check whether the air conditioner is operable (ON/OFF and the air flow adjustment)
Related infor-
on the air conditioner screen.
mation
q If the air conditioner is operable, wiring harness (CAN communication line) does not have a ground fault,
q Since each controller and machine monitor (meter unit) are connected directly to the battery, they are sup-
plied with power even after the starting switch is turned to OFF position.

1 Perform troubleshooting for failure code [DBC3KK].
ABS controller
cation line
4
HD465-8, HD605-8 40-849

FAILURE CODE [DBCQMA] 40 TROUBLESHOOTING
FAILURE CODE [DBCQMA]

Action level Failure code Option Selection (ABS Controller) Inconsistency
Failure
L03 DBCQMA (ABS controller system)
Details of fail- When the starting switch is turned to ON position, the option selection information sent from the monitor con-
ure troller differs from the option settings stored in the ABS controller.
q Controls with the option settings stored in the ABS controller.
Effect of con-
troller
Effect on the
Front brake off function may not work as designed (the settings in the machine monitor are not reflected).
machine

The option setting of machine monitor is probably incorrect. After replacing the machine
Defective alternative equip- monitor or ABS controller, set the options correctly. For details, see TEST AND ADJUST.
1 ment setting of the REMARK
machine monitor Perform initial setting and initial adjustment similar to those required when the ABS con-
troller is replaced.
40-850 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DBCRKR]
FAILURE CODE [DBCRKR]

Action level Failure code CAN1 Defective Communication (ABS Controller)
Failure
L03 DBCRKR (Detected by monitor controller) (Machine monitor system)
Details of fail- Monitor controller does not obtain information from the ABS controller on CAN1 communication line (KOM-
ure NET/r).
Effect of con-
Retain information before the failure occurrence.
troller
Effect on the q ABS system may not be operating normally.
machine q Machine monitor does not display information from the ABS controller.
ler are [DAQRKR], [DB1RKR], [DB2RKR], and [DBVRKR]. When the failure codes [DAQRKR],
[DB1RKR], [DB2RKR], and [DBVRKR] are also displayed, ground fault, short circuit, or hot short in wiring
Related infor- harness (CAN communication line) can be suspected.
q Since each controller and the monitor controller are connected directly to the battery, they are supplied
with power even after starting switch is turned to OFF position.

1 Perform troubleshooting for failure code [DBC3KK].
ABS controller
cation line
4
HD465-8, HD605-8 40-851

FAILURE CODE [DBV0MC] 40 TROUBLESHOOTING
FAILURE CODE [DBV0MC]

Action level Failure code KOMTRAX Plus Malfunction
Failure
- DBV0MC (KOMTRAX Plus controller system)
Details of fail- q Internal supply voltage error in KOMTRAX Plus controller

ure q CPU error in KOMTRAX Plus controller
Effect of con-
Set controller CPU again, and then start it again.
troller
Event on
To show the load weight capacity and record data, wait until the machine completely starts again.
machine
mation Procedure turn the start switch to the ON position.

Defective KOMTRAX Plus KOMTRAX Plus controller is defective. (Since this is an internal defect, you cannot trou-
1
40-852 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DBV1KK]
FAILURE CODE [DBV1KK]

Action level Failure code Controller Power Supply Voltage Low (KOMTRAX Plus)
Failure
L01 DBV1KK (KOMTRAX Plus controller system)
Details of fail- Continuous power supply voltage of the KOMTRAX Plus controller decreases below 17 V while the engine
ure operates.
Effect of con- q None in particular
troller q Repairs when the power supply voltage becomes 17 V and higher.
Effect on the
If the battery voltage lowers to 10 V or lower, function of KOMTRAX Plus controller stops.
machine
q If failure code [AB00KE] is shown, battery charged is defective. Troubleshoot for it first.
Related infor-
mation

Battery voltage (per 1 battery) Min. 12 V
1 Defective battery
Battery voltage (2 batteries in-line) Min. 24 V

2. Disconnect connector KPS2, and connect T-adapter to the female side.
Between KPS2 (female) (8) and (6) Min. 17 V
2
ness Between KPS2 (female) (9) and (7) Min. 17 V
Voltage
Defective KOMTRAX Plus If there is no failure with the checks above, KOMTRAX Plus controller is defective. (Since
3
HD465-8, HD605-8 40-853

FAILURE CODE [DBV1KK] 40 TROUBLESHOOTING
Circuit diagram related to KOMTRAX Plus controller power supply
40-854 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DBV6KB]
FAILURE CODE [DBV6KB]

Action level Failure code 24V Sensor Power Voltage System Ground Fault (KOMTRAX Plus)
Failure
L01 DBV6KB (KOMTRAX Plus controller system)
Details of fail-
KOMTRAX Plus controller detects 24 V power output ground fault.
ure
troller q Restores by the starting switch is turned to OFF position.
Effect on the Exhaust temperature, longitudinal tilt, suspension pressure, and load weight capacity are not correctly shown
machine or recorded.

2. Disconnect any one of connectors described below.
4. If this failure code is not displayed, the sensor of the disconnected connector is defec-
tive.
REMARK
Failure code for the open circuit of the disconnected sensor appears due to disconnecting
Defective exhaust temper- the connector.
ature sensor, tilt angle sen- 5. Disconnect other connectors one by one, and repeat step 1 to 4 to check.
1
sor, and suspension
cylinder pressure sensor Exhaust temperature sensor HM23A
Incline angle sensor PM3
Suspension cylinder pressure sensor (FL) SUFL
Connector
Suspension cylinder pressure sensor (FR) SUFR
Suspension cylinder pressure sensor (RL) SURL
Suspension cylinder pressure sensor (RR) SURR

2. Disconnect connectors KPS2, HM23A, PM3, SUFL, SUFR, SURL, SURR, and
2 KPS2 (female) (49) and HM23A (female) (A), and PM3
ness
(female) (C)
SUFL (female) (B), SUFR (female) (B), SURL (female) (B)
Between SURR (female) (B) and ground
3
HD465-8, HD605-8 40-855

FAILURE CODE [DBV6KB] 40 TROUBLESHOOTING
Circuit diagram related to KOMTRAX Plus controller 24 V sensor power supply
40-856 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DBV7KB]
FAILURE CODE [DBV7KB]

Action level Failure code 12V Sensor Power Voltage System Ground Fault (KOMTRAX Plus)
Failure
L01 DBV7KB (KOMTRAX Plus controller system)
Details of fail-
KOMTRAX Plus controller senses 12 V power output ground fault.
ure
troller q Restores by the starting switch is turned to OFF position.
Effect on the
Data Received display (on the side of cab) for the load meter does not illuminate.
machine

2. Disconnect the connector Data Received display (on the side of cab) for the load
meter.
Defective Data Received 3. Turn the start switch to the ON position.
1
display (on the side of cab)
4. If this failure code is not shown, the disconnected display is defective.
Data Received display (on the side of cab) for the load
Connector SPA
meter

Ground fault in wiring har- 2. Disconnect connectors KPS2 and SPA, and connect T-adapter to either female side.
2
ness Between ground and KPS2 (female) (15) or SPA (female)
(1)
3
Circuit diagram related to KOMTRAX Plus controller 12 V sensor power supply
HD465-8, HD605-8 40-857

FAILURE CODE [DBVLKA] 40 TROUBLESHOOTING
FAILURE CODE [DBVLKA]

Action level Failure code System Operating Lamp Open Circuit (KOMTRAX Plus)
Failure
- DBVLKA (KOMTRAX Plus controller system)
KOMTRAX Plus controller found an open circuit because the output line voltage of the system operating lamp
Details of fail-
is 4 to 6 V during approximately 3 seconds. This occurs when the KOMTRAX Plus controller is not energized
ure
after the start switch is turned to ON.
Effect of con-
troller
Effect on the
System operating lamp does not illuminate while the controller starts or stops.
machine
q Although the KOMTRAX Plus controller cannot light the system operation lamp, there will be no trouble
Related infor- q An open circuit is found because no controllers energize the system operation lamp for approximately 3
mation seconds after the start switch is turned to ON.

1 Defective fuse If fuse No. 14 in fuse case BT4 is blown, the circuit probably has a ground fault.

2. While this failure code is shown, the condition of the system operation lamp is not
ness
4. Disconnect connectors KPS2 and OPL, and connect T-adapter to each female side.
Between FUSE BT4-28 and OPL (female) (1) Max. 1 Ω
Resistance
Between KPS2 (female) (10) and OPL (female) (2) Max. 1 Ω

3
4. Disconnect connector OPL, and connect T-adapter to the female side.
4
40-858 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DBVLKA]
HD465-8, HD605-8 40-859

FAILURE CODE [DBVLKA] 40 TROUBLESHOOTING
40-860 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DBVLKB]
FAILURE CODE [DBVLKB]

Action level Failure code System Operating Lamp Short Circuit (KOMTRAX Plus)
Failure
- DBVLKB (KOMTRAX Plus controller system)
Details of fail- KOMTRAX Plus controller senses a short circuit. Because, voltage of the output circuit does not become a
ure low level (5 V or below) although the KOMTRAX Plus controller puts out current to the system operation lamp.
Effect of con-
troller
Effect on the
System operation lamp illuminates continuously.
machine
q Although the KOMTRAX Plus controller cannot light the system operation lamp, there will be no trouble
Related infor- q An open circuit is found because no controllers energize the system operation lamp for approximately 3
mation seconds after the start switch is turned to ON.

2. While this failure code is shown, the condition of the system operation lamp is not
1
harness 3. Disconnect connector OPL, and connect a T-adapter to the female side.
Defective KOMTRAX Plus If no ok is found by the above checks, KOMTRAX Plus controller is defective. (Since this
2
controller is an internal defect, you cannot troubleshoot.)
HD465-8, HD605-8 40-861

FAILURE CODE [DBVLKB] 40 TROUBLESHOOTING
40-862 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DBVLKB]
HD465-8, HD605-8 40-863

FAILURE CODE [DBVQKR] 40 TROUBLESHOOTING
FAILURE CODE [DBVQKR]

Action level Failure code CAN2 Defective Communication (KOMTRAX Plus)
Failure
- DBVQKR (Detected by monitor controller) (Machine monitor system)
Details of fail- Monitor controller does not recognize the KOMTRAX Plus controller on CAN2 communication line (KOM-
ure NET/c).
Effect of con-
Does not update communication information with the KOMTRAX Plus controller.
troller
Effect on the q Failure codes related to the KOMTRAX Plus controller are not shown.
machine q Monitored data related to the KOMTRAX Plus controller are not up-dated.
q 6 different failure codes, [DBQQKR], [DAZQKR], [DB1QKR], [DB2QKR], [DBVQKR] and [DSJ0KR] are used
for the defective CAN communication by CAN 2. The monitor controller found them. When all 6 of these failure
codes are shown, ground fault, short circuit, or hot short circuit in wiring harness (CAN communication line)
are possible. The air conditioner is also operated through the CAN communication. Make sure the air condi-
Related infor- tioner is operable (ON and OFF and the airflow adjusts) on the air conditioner screen.
mation REMARK
turned to OFF.

1 Perform checks on causes 1 to 2 for failure code [DBV1KK].
cation system
3
controller this is an internal defect, you cannot troubleshoot.)
4
40-864 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DBVRKR]
FAILURE CODE [DBVRKR]

Action level Failure code CAN1 Defective Communication (KOMTRAX Plus)
Failure
- DBVRKR (Found by monitor controller) (Machine monitor system)
Details of fail- Monitor controller does not recognize the KOMTRAX Plus controller on CAN1 communication line (KOM-
ure NET/r).
Effect of con-
Does not update communication information with the KOMTRAX Plus controller.
troller
Effect on the
Speed limit during over load function may not operate.
machine
q Other failure codes of the defective CAN communication through CAN1, detected by the monitor controller are
[DAQRKR], [DB1RKR], and [DB2RKR]. When failure codes [DAQRKR], [DB1RKR], or [DB2RKR] are also
shown, ground fault, short circuit, or hot short in wiring harness (CAN communication line) is suspect.
mation Machine with ABS system also displays failure code [DBCRKR].
turned to OFF.

1 Perform checks on causes 1 to 2 for failure code [DBV1KK].
cation system
Defective KOMTRAX Plus If no failure is found by the above checks, KOMTRAX Plus controller is defective. (Since
3
4
HD465-8, HD605-8 40-865

FAILURE CODE [DBVVKR] 40 TROUBLESHOOTING
FAILURE CODE [DBVVKR]

Action level Failure code LAN 1 Defective Communication
Failure
- DBVVKR (KOMTRAX Plus controller system)
Details of fail-
Defective communication with the device connected to LAN port 1 of KOMTRAX Plus controller is found.
ure
Effect of con-
None in particular
troller
Effect on the
None in particular
machine
q Abnormality detection can be set.
Related infor-
(See Service Menu→Default→KOMTRAX Plus Settings.)
mation
q This failure does not occur, because the setting to detect LAN port 1 failure is usually disabled.

Defective LAN port con- Make sure the LAN wire bundle connector is connected to LAN port 1 (KPS4) of the KOM-
1
nection TRAX Plus controller
2 LAN cable has open circuit. Check if LAN cable has open circuit.
3
40-866 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DBVWKR]
FAILURE CODE [DBVWKR]

Action level Failure code LAN 2 Defective Communication
Failure
- DBVWKR (KOMTRAX Plus controller system)
Details of fail-
Defective communication with the device connected to LAN port 2 of KOMTRAX Plus controller is found.
ure
Effect of con-
None in particular
troller
Effect on the
Wireless LAN does not work.
machine
q Problem search is available
Related infor- (See Service Menu→Default→KOMTRAX Plus Settings.)
mation q This failure does not occur. Because, the setting to detect LAN port 2 failure is disabled when there is no
wire less LAN (alternative equipment).

Defective LAN port con- Check if the LAN wire bundle connector is connected to LAN port 2 (KPS5) of the KOM-
1
nection TRAX Plus controller and LAN port of the wire less LAN unit.
2 LAN wire has open circuit. Check if LAN wire has open circuit.
Defective wire less LAN Wire less LAN unit is defective. (Since this is an internal problem, you cannot trouble-
3
unit shoot.)
4
HD465-8, HD605-8 40-867

FAILURE CODE [DDAAL6] 40 TROUBLESHOOTING
FAILURE CODE [DDAAL6]

Action level Failure code Engine Shutdown Secondary Switch Open Circuit
Failure
L03 DDAAL6 (Machine monitor system)
Details of fail-
Monitor controller finds open circuit in the engine shutdown secondary switch circuit.
ure
Effect of con-
None in particular
troller
Effect on the
The machine monitor shows the display with the engine shutdown secondary switch in the ON position.
machine

Operation of the engine
1 shutdown secondary Make sure the engine shutdown secondary switch is in the OFF position.
switch

2. Engine shutdown secondary switch in the OFF position
Defective engine shut- 3. Disconnect connector ESS, and connect T-adapter to the male side.
2
Resistance

4. Disconnect connector MCM1, and connect T-adapter to the female side.
Resistance Between MCM1 (female) (24) and (31) Max. 1 Ω
Open circuit in wiring har- If no failure is found by the previous checks, this check is not required.
3
ness 1. Turn the start switch to the OFF position.
3. Disconnect connectors MCM1 and ESS, and connect T-adapter to each female side.
Between ESS (female) (2), (5) and MCM1 (female) (24)
Max. 1 Ω
Resistance (43)
Between ESS (female) (1), (4) and MCM1 (female) (31) Max. 1 Ω
4
40-868 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DDAAL6]
Circuit diagram related to monitor controller power supply
HD465-8, HD605-8 40-869

FAILURE CODE [DDAAL6] (For machines equipped with emergency engine
FAILURE CODE [DDAAL6] (For machines equipped with emer-

Action level Failure code Engine Shutdown Secondary Switch Open Circuit
Failure
L03 DDAAL6 (Machine monitor system)
Details of fail-
Monitor controller finds open circuit in the engine shutdown secondary switch circuit.
ure
Effect of con-
None in particular
troller
Effect on the
The machine monitor shows the display with the engine shutdown secondary switch in the ON position.
machine

Operation of the engine
1 shutdown secondary Make sure the engine shutdown secondary switch is in the OFF position.
switch
Operation of the emer-
2 Check that the emergency engine stop switch is in OFF position.
gency engine stop switch

Defective engine shut- 3. Disconnect connector ESS, and connect T-adapter to the male side.
3
Resistance

2. Disconnect connectors SES, SES2, and ESS, and connect T-adapter to each female
side.
Defective emergency
4 Between SES (female) (1) and (2) Max. 1 Ω
engine stop switch
Resistance Between ML01_M (female) (5) and (6) Max. 1 Ω
Between ESS_M (male) (1) and ground Max. 1MΩ
Between SES (female) (1) and ground Max. 1MΩ
Between ML01_M (female) (6) and ground Max. 1MΩ
40-870 HD465-8, HD605-8


4. Disconnect connector MCM1, and connect T-adapter to the female side.
Resistance Between MCM1 (female) (24) and (31) Max. 1 Ω
Open circuit in wiring har- If no failure is found by the previous checks, this check is not required.
5
ness 1. Turn the start switch to the OFF position.
3. Disconnect connectors MCM1 and ESS, and connect T-adapter to each female side.
Between ESS (female) (2), (5) and MCM1 (female) (24)
Max. 1 Ω
Resistance (43)
Between ESS (female) (1), (4) and MCM1 (female) (31) Max. 1 Ω
6
HD465-8, HD605-8 40-871

Circuit diagram related to monitor controller power supply (For machines equipped with emergency engine stop
switch)
40-872 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DDACL4]
FAILURE CODE [DDACL4]

Action level Failure code Machine Lockout Switch Failure
Failure
L03 DDACL4 (Transmission controller system)
Details of fail-
Information differs between signal 1 and signal 2 from the machine lockout.
ure
Effect of con-
Determines that conditions for activating the machine lockout function are not established.
troller
q Machine lockout function cannot be activated.
Effect on the
q If the machine lockout function is working, the lockout function cannot be canceled until the starting switch
machine
q If failure codes [DDACL4] and [DDADKA] are displayed at the same time, the fuse No. 11 in the fuse box
BT5 may be broken.
q If failure codes [DAQ2KK], [DDACL4], and [DDADKA] are displayed at the same time, perform trouble-
Related infor-
shooting for [DAQ2KK].
mation
q Check the machine lockout switch input state (ON/OFF) with monitoring function. (Code: 02213)


2. Disconnect connector MLS, and connect T-adapter to male side.
Between MSL (male) (2) and Switch: OFF Max. 1 Ω
Defective machine lockout (1) and between MSL (male)
2 Switch: ON Min. 1 MΩ
switch (5) and (4)
Resistance
Between MSL (male) (2) and Switch: OFF Min. 1 MΩ
(3) and between MSL (male)
(5) and (6) Switch: ON Max. 1 Ω

2. Disconnect connectors ATC1 and MLS, and connect T-adapter to each female side.
3. Remove fuse No. 11 in fuse box BT5.
3 Between ATC1 (female) (17) and MLS (female) (3) or (6) Max. 1 Ω
ness
Resistance Between ATC1 (female) (24) and MLS (female) (1) or (5) Max. 1 Ω
Between MLS (female) (2) or (5) and BT5-22 Max. 1 Ω

3. Disconnect connectors ATC1 and MLS, and connect T-adapter to either female side.
Ground fault in wiring har- Between ground and ATC1 (female) (17) or MLS (female)
4 Min. 1 MΩ
ness (3) or (6)
Resistance Between ground and ATC1 (female) (24) or MLS (female)
Min. 1 MΩ
(1) or (4)
Between ground and MLS (female) (2) or (5) or BT5-22 Min. 1 MΩ
HD465-8, HD605-8 40-873

FAILURE CODE [DDACL4] 40 TROUBLESHOOTING

2. Disconnect connectors ATC1 and MLS, and connect T-adapter to either female side.
5 Between ground and ATC1 (female) (17) or MLS (female)
harness Max. 1 V
(3) or (6)
Voltage
Between ground and ATC1 (female) (24) or MLS (female)
Max. 1 V
(1) or (4)

2. Put a T-adapter into connector ATC1.
Defective transmission Between ATC1 (17) and Switch: OFF Max. 1 V
6
controller ground Switch: ON 20 to 30 V
Voltage
Between ATC1 (24) and Switch: OFF 20 to 30 V
ground Switch: ON Max. 1 V
Circuit diagram related to machine lockout switch
40-874 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DDADKA]
FAILURE CODE [DDADKA]

Action level Failure code Machine Lockout Work Lamp Failure
Failure
L03 DDADKA (Transmission controller system)
Details of fail- When the controller does not drive the machine lockout work lamp circuit, the output line voltage of the
ure machine lockout work lamp is 5.7 V or below.
Effect of con- Even if the cause of failure is eliminated, the machine does not return to normal until the starting switch is
troller turned to OFF position.
Effect on the q If an open circuit occurs, the machine lockout work lamp does not light up.
machine q If a ground fault occurs, the machine lockout work lamp does not go out.
q If failure codes [DDACL4] and [DDADKA] are displayed at the same time, the fuse No. 11 in the fuse box
BT5 may be broken.
q If failure codes [DAQ2KK], [DDACL4], and [DDADKA] are displayed at the same time, perform trouble-
Related infor- shooting for failure code [DAQ2KK] first.
mation q Check the output state of the machine lockout work lamp (ON/OFF) with monitoring function. (Code:
03706)


2. Disconnect connectors ATC2, MLL, R18, and RE9, and connect T-adapter to each
2
ness
Between ATC2 (female) (21) and MLL (female) (2) Max. 1 Ω
Resistance
Between MLL (female) (1) and R18 (female) (3) Max. 1 Ω

female side.
3
ness Between ground and ATC2 (female) (21) or MLL (female)
Min. 1 MΩ
Resistance (2)
Between ground and MLL (female) (1) or R18 (female) (3) Min. 1 MΩ

female side.
4
ness Between MLL (female) (1) and (2) No continuity
Continuity Between ATC2 (female) (21) and each pin other than pin
No continuity
(21)
5
HD465-8, HD605-8 40-875

FAILURE CODE [DDADKA] 40 TROUBLESHOOTING
Circuit diagram related to machine lockout work lamp
40-876 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DDADKY]
FAILURE CODE [DDADKY]

Action level Failure code Machine Lockout Work Lamp Hot Short
Failure
L03 DDADKY (Transmission controller system)
Details of fail- When the controller drives the machine lockout work lamp circuit, the output line voltage of the machine lock-
ure out work lamp is 5.7 V or above.
q Stops driving the machine lockout work lamp.
Effect of con-
troller
Effect on the
Machine lockout work lamp does not light up.
machine
q Check the output state of the machine lockout work lamp (ON/OFF) with monitoring function. (Code:
Procedure: Turn the starting switch to ON position and activate the machine lockout work function.

Hot short circuit in wiring 3. Disconnect connector ATC2, and connect T-adapter to female side.
1
harness
Voltage Between ATC2 (female) (21) and ground Max. 1 V

female side.
2
ness Between MLL (female) (1) and (2) No continuity
No continuity
(21)
3
Circuit diagram related to machine lockout work lamp
HD465-8, HD605-8 40-877

FAILURE CODE [DDD7KX] 40 TROUBLESHOOTING
FAILURE CODE [DDD7KX]

Action level Failure code Travel Speed Setting Switch System Abnormality
Failure (When the ARSC is set)
L03 DDD7KX (Retarder and hoist controller system)
Details of fail-
Voltage of the input signal circuit in the vehicle speed setting switch is 0.3 V or lower.
ure
Effect of con-
Releases the brake gradually when ARSC is in operation.
troller
Effect on the
ARSC does not work.
machine
Related infor-
mation

2. Replace the vehicle speed setting switch (ARSC SET switch)
Defective vehicle speed Replace the Switch is nor-

Machine does not go back to normal.
1 setting switch (ARSC SET vehicle mal.
switch) speed set-
ting switch Switch is
(ARSC SET The machine goes back to normal.
defective.
switch)

2 Defective resistor (250 Ω) 2. Disconnect connector RE3.
Resistance Between RE3 (male) (1) and (2) 250±25 Ω

3 Defective resistor (1020 Ω) 2. Disconnect connector RE4.

2. Disconnect connectors BRC1 and ARC, and connect T-adapter to each female side.
Between BRC1 (female) (22) and (23) 250±25 Ω
4
ness Between BRC1 (female) (22) and ARC (female) (1) 250±25 Ω
Resistance
Between BRC1 (female) (21) and ARC (female) (3) Max. 1 Ω
Between BRC1 (female) (21) and ARC (female) (2) 1020±102 Ω

2. Disconnect connectors BRC1, RE1, SAC, J07, and ARC, and connect T-adapter to
Ground fault in wiring har- female side of BRC1.
5
ness
Between BRC1 (female) (22) and ground Min. 1 MΩ
Resistance

2. Disconnect connector RE1, RE3, RE4, J07, and SAC.
3. Put a T-adapter into connector BRC1.
hoist controller
Voltage Between BRC1 (22) and (21) 4.6 to 5.4 V
40-878 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DDD7KX]
Circuit diagram related to travel Speed Setting Switch
HD465-8, HD605-8 40-879

FAILURE CODE [DDP6L4] 40 TROUBLESHOOTING
FAILURE CODE [DDP6L4]

Action level Failure code Service brake pressure switch Malfunction
Failure
L03 DDP6L4 (ABS controller detects) (ABS controller system)
When both foot brake pressure switch and retarder brake pressure sensor are considered to be in the OFF
Details of fail-
state, the input voltage of the signal circuit in the ABS control valve pressure sensor (rear right) or ABS con-
ure
trol valve pressure sensor (rear left) becomes 2.5 V to 4.7 V.
Effect of con-
troller
q ABS does not work.
Effect on the
q Front brake cut does not function and the front brake works.
machine
q Stop lamp does not light up even if the brake is operated.
q If failure code [DHUPKX] is also displayed, perform troubleshooting for it first.
Related infor-
mation
Procedure: Start the engine and operate the brake pedal.

2. Disconnect connector S01, and connect T-adapter to male side.
Defective foot brake pres- Brake opera-
1
sure switch tion: Continu-
ity
Continuity Between S01 (male) (A) and (B)
Brake
release: No
continuity

2. Disconnect connectors BRC2, BRC3, and S01, and connect T-adapter to each female
2
ness
Between BRC2 (female) (12) and S01 (female) (A) Max. 1 Ω
Resistance
Between BRC3 (female) (21) and S01 (female) (B) Max. 1 Ω

2. Disconnect connectors BRC2, BRC3, and S01, and connect T-adapter to female side
Ground fault in wiring har- of S01.
3
ness
Between S01 (female) (A) and ground Min. 1 MΩ
Resistance
Between S01 (female) (B) and ground Min. 1 MΩ
Defective hydraulic system
4 (When the electrical sys- Hydraulic system may be defective. Repair the cause of failure.
tem works properly)
Defective retarder and If no failure is found by the above checks, the retarder and hoist controller is defective.
5
hoist controller (Since this is an internal defect, troubleshooting cannot be performed.)
40-880 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DDP6L4]
Circuit diagram related to foot brake pressure switch
HD465-8, HD605-8 40-881

FAILURE CODE [DDTHKA] 40 TROUBLESHOOTING
FAILURE CODE [DDTHKA]

Action level Failure code Fill Switch Open Circuit (High Clutch)
Failure
L01 DDTHKA (Transmission controller system)
Details of fail- When the H clutch ECMV solenoid is energized, the clutch engages but the signal from the fill switch is not
ure turned to “ON”.
Effect of con- q No longer operates the primary pressure adjustable solenoid.
troller q No longer operates the primary flow flexible solenoid.
Effect on the Primary pressure variable solenoid and primary flow selector solenoid do not function and fuel consumption
machine may decrease.
k Before you perform this procedure, raise the body to the maximum height and be sure to set the
hoist lever to "HOLD". Set the lock knob to LOCK, and engage the body pivot pin.
Related infor-
mation q The monitor function checks the fill switch input signal. (Code: 02216)

2. While the brake pedal is depressed, move the gear shift lever to L and gear speed to
F1 (Lo: 1st). Make sure that failure code [DDTJKA] is not shown.
4. Replace the connectors H clutch with L clutch.
q H, PS ←→ L, PS
q H, SW ←→ L, SW
Defective H clutch ECMV
1 5. Start the engine.
fill switch
F1 (Lo: 1st).
q If failure code [DDTJKA] appears, examine the clutch oil pressure. If the oil pressure
is normal, H clutch fill switch is defective.
q If the failure code [DDTJKA] does not appear, the wiring harness has an open circuit
or transmission controller is defective.
After you finish the test, replace the connector.

Open circuit in wiring har- 2. Disconnect connectors ATC3 and H, SW, and connect T-adapter to each female side.
2
ness
Resistance Between ATC2 (female) (27) and H, SW (female) (1) Max. 1 Ω
3
40-882 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DDTHKA]
HD465-8, HD605-8 40-883

FAILURE CODE [DDTJKA] 40 TROUBLESHOOTING
FAILURE CODE [DDTJKA]

Action level Failure code Fill Switch Open Circuit (Low Clutch)
Failure
L01 DDTJKA (Transmission controller system)
Details of fail- When L clutch ECMV solenoid is energized, the clutch engages but the signal from the fill switch is not turned
ure to “ON”.
troller q No longer operates the primary flow selector solenoid.
Effect on the Main pressure variable solenoid and main flow selector solenoid do not function and fuel consumption may
machine decrease.
lever to "HOLD". Set the lock knob to LOCK, and engage the body pivot pin.
Related infor-

2. Replace the connectors H clutch with L clutch.
q L, PS ←→ H, PS
q L, SW ←→ , SW
Defective L clutch ECMV 4. While the brake pedal is depressed, move the gear shift lever to I and gear speed to
1
fill switch F1 (Lo: 1st).
q If failure code [DDTJKA] does not appear, examine the clutch oil pressure. If the oil
pressure is normal, L clutch fill switch is defective.
q If failure code [DDTJKA] appears, the wiring harness has an open circuit or transmis-
sion controller is defective.
After you complete the test, replace the connector.

Open circuit in wiring har- 2. Disconnect connectors ATC3 and L, SW, and connect T-adapter to each female side.
2
ness
Resistance Between ATC2 (female) (37) and L, SW (female) (1) Max. 1 Ω
3
40-884 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DDTJKA]
HD465-8, HD605-8 40-885

FAILURE CODE [DDTKKA] 40 TROUBLESHOOTING
FAILURE CODE [DDTKKA]

Action level Failure code Fill Switch Open Circuit (1st Clutch)
Failure
L01 DDTKKA (Transmission controller system)
Details of fail- When 1st clutch ECMV is energized, the clutch engages but the signal from the fill switch is not turned to
ure “ON”.
lever to "HOLD". Set the lock knob to LOCK, and engage the body pivot pin.
Related infor-

2. While the brake pedal is depressed, move the gear shift lever to R and gear speed to
R (Lo: R). Make sure that failure code [DDTNKA] is not shown.
4. Replace the connectors 1st clutch with R clutch.
q 1, PS ←→ R, PS
q 1, SW ←→ R, SW
Defective 1st clutch ECMV
fill switch
R (Lo: R).
q If failure code [DDTNKA] appears, examine the clutch oil pressure. If the oil pressure
is normal, 1st clutch fill switch is defective.
q If the failure code [DDTJKA] does not appear, the wiring harness has an open circuit
or transmission controller is defective.

Open circuit in wiring har- 2. Disconnect connectors ATC2 and 1, SW, and connect T-adapter to each female side.
2
ness
Resistance Between ATC2 (female) (12) and 1, SW (female) (1) Max. 1 Ω
3
40-886 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DDTKKA]
HD465-8, HD605-8 40-887

FAILURE CODE [DDTLKA] 40 TROUBLESHOOTING
FAILURE CODE [DDTLKA]

Action level Failure code Fill Switch Open Circuit (2nd Clutch)
Failure
L01 DDTLKA (Transmission controller system)
Details of fail- When 2nd clutch ECMV is energized, the clutch engages but the signal from the fill switch is not turned to
ure “ON”.
Effect of con- q No longer operates the primary pressure variable solenoid.
k Before you perform the below procedure, raise the body to the maximum height. Make sure to set
the hoist lever to "HOLD". Set the lock knob to LOCK, and engage the body pivot pin.
Related infor-

R (Lo: R). Make sure that failure code [DDTNKA] is not shown.
4. Replace the connectors 2nd clutch with R clutch.
q 2, PS ←→ R, PS
q 2, SW ←→ R, SW
ECMV fill switch
R (Lo: R).
q If failure code [DDTNKA] appears, examine the clutch oil pressure. If the oil pressure
is normal, 2nd clutch fill switch is defective.
q If failure code [DDTJKA] does not appear, the wiring harness has an open circuit or
transmission controller is defective.

2
ness
3
40-888 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DDTLKA]
HD465-8, HD605-8 40-889

FAILURE CODE [DDTMKA] 40 TROUBLESHOOTING
FAILURE CODE [DDTMKA]

Action level Failure code Fill Switch Open Circuit (3rd Clutch)
Failure
L01 DDTMKA (Transmission controller system)
Details of fail- When 3rd clutch ECMV is energized, the clutch engages but the signal from the fill switch is not turned to
ure “ON”.
Related infor-

2. While the brake pedal is depressed, move the gear shift lever to D and gear speed to
F2 (Lo: 2nd). Make sure that failure code [DDTLKA] is not shown.
4. Replace the 3rd clutch connectors with the 2nd clutch connectors.
q 3, PS ←→ 2, PS
q 3, SW ←→ 2, SW
Defective 3rd clutch ECMV
fill switch
F2 (Lo: 2nd).
q If failure code [DDTLKA] appears, examine the clutch oil pressure. If the oil pressure
is normal, 3rd clutch fill switch is defective.
q If failure code [DDTLKA] does not appear, the wiring harness has an open circuit or
After you complete the test, replace the connector.

2
ness
3
40-890 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DDTMKA]
HD465-8, HD605-8 40-891

FAILURE CODE [DDTNKA] 40 TROUBLESHOOTING
FAILURE CODE [DDTNKA]

Action level Failure code Fill Switch Open Circuit (Reverse Clutch)
Failure
L01 DDTNKA (Transmission controller system)
Details of fail-
When R clutch ECMV is energized, the clutch engages but the signal from the fill switch is not turned to “ON”.
ure
Related infor-
Procedure: Start the engine and operate the machine in R.

F1 (Lo: 1st). Make sure that failure code [DDTLKA] is not shown.
4. Replace the R clutch connectors with the 1st clutch connectors.
q R, PS ←→ 1, PS
q R, SW ←→ 1, SW
Defective R clutch ECMV
fill switch
F1 (Lo: 1st).
q If failure code [DDTLKA] appears, examine the clutch oil pressure. If the oil pressure
is normal, H clutch fill switch is defective.
q If failure code [DDTLKA] does not appear, the wiring harness has an open circuit or

Open circuit in wiring har- 2. Disconnect connectors ATC3 and R, SW, and connect T-adapter to each female side.
2
ness
Resistance Between ATC3 (female) (29) and R, SW (female) (1) Max. 1 Ω
3
40-892 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DDTNKA]
HD465-8, HD605-8 40-893

FAILURE CODE [DDTPKA] 40 TROUBLESHOOTING
FAILURE CODE [DDTPKA]

Action level Failure code Fill Switch Open Circuit (4th Clutch)
Failure
L01 DDTPKA (Transmission controller system)
Details of fail- When 4th clutch ECMV is energized, the clutch engages but the signal from the fill switch is not turned to
ure “ON”.
q The monitor function checks the fill switch input signal. (Code: 02229)
Related infor-
q After the repair is completed, make sure the failure code deletes. Use the procedure which follows.
mation

F2 (Lo: 2nd). Make sure that failure code [DDTJKA] is not shown.
4. Replace the connectors 4th clutch with L clutch.
q 4, SP ←→ L, PS
q 4, SW ←→ L, SW
Defective 4th clutch ECMV
fill switch
F2 (Lo: 2nd).
q If failure code [DDTJKA] appears, examine the clutch oil pressure. If the oil pressure
is normal, 4th clutch fill switch is defective.
q If failure code [DDTJKA] does not appear, the wiring harness has an open circuit or
Replace the connector after you finish the test.

Open circuit in wiring har- 2. Disconnect connectors ATC2 and 4,SW, and connect T-adapter to each female side.
2
ness
3
40-894 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DDTPKA]
Circuit diagram related to the 4th clutch
HD465-8, HD605-8 40-895

FAILURE CODE [DF10KA] 40 TROUBLESHOOTING
FAILURE CODE [DF10KA]

Action level Failure code T/M Shift Lever Input Signal Open Circuit
Failure
L03 DF10KA (Transmission controller system)
Details of fail-
No input of gear shift lever signal
ure
Effect of con-
Controls machine by using the lever information before the failure occurrence.
troller
q Transmission may shift into higher gear speed than the one selected by gear shift lever.
Effect on the q Transmission is held in neutral and the machine cannot start.
machine q Steering selections are not performed.
q All gear shift lever position lamps go out.
q The monitor function checks the input signal (ON, OFF) from the gear shift lever. (Code: 02211)
Related infor-
mation

q Apply force in addition to the force to operate the gear shift lever. It depresses the le-
Defective operation of gear
1 ver.
shift lever
q Gear shift lever is stopped in between 2 positions.

3. Disconnect connectors SF1, ATC1, ATC2, and ATC3, and connect T-adapter to each
female side.
Between BT4-6 and SF1 (female) (1) Max. 1 Ω
Between ATC2 (female) (35) and SF1 (female) (3) Max. 1 Ω
2 Between ATC2 (female) (15) and SF1 (female) (6) Max. 1 Ω
ness
Resistance
Between ATC3 (female) (21), (31), (32), (33) and SF1
Max. 1 Ω
(female) (2)
40-896 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DF10KA]

2. Disconnect connectors ATC1, ATC2, and SF1, and connect T-adapter to each female
side.
Between ground and ATC2 (female) (35) or SF1 (female)
Min. 1 MΩ
(3)
Between ground and ATC1 (female) (6) or SF1 (female) (4) Min. 1 MΩ
Min. 1 MΩ
(5)
Ground fault in wiring har- Min. 1 MΩ
3 (6)
ness
Between ground and ATC2 (female) (5) or SF1 (female) (7) Min. 1 MΩ
Resistance
Min. 1 MΩ
(8)
Min. 1 MΩ
(9)
Min. 1 MΩ
(10)
Min. 1 MΩ
(11)
HD465-8, HD605-8 40-897

FAILURE CODE [DF10KA] 40 TROUBLESHOOTING

2. Put a T-adapter into connector SF1.
4. Operate the gear shift lever to troubleshoot
In shift range "R" 20 to 30 V
Between SF1 (3) and
ground In any shift range other than
Max. 1 V
"R"
In shift range "N" 20 to 30 V
Between SF1 (4) and
Max. 1 V
"N"
In shift range "D" 20 to 30 V
Between SF1 (5) and
Max. 1 V
"D"
In shift range "6" 20 to 30 V
Between SF1 (6) and
Max. 1 V
4 Defective gear shift lever "6"
Between SF1 (7) and
Voltage In any shift range other than
ground Max. 1 V
"5"
Between SF1 (8) and
Max. 1 V
"4"
Between SF1 (9) and
Max. 1 V
"3"
Between SF1 (10) and
Max. 1 V
"2"
In shift range "L" 20 to 30 V
Max. 1 V
"L"
5
40-898 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DF10KA]
Circuit diagram related to transmission gear shift lever
HD465-8, HD605-8 40-899

FAILURE CODE [DF10KB] 40 TROUBLESHOOTING
FAILURE CODE [DF10KB]

Action level Failure code T/M Shift Lever Input Signal Short Circuit
Failure
L03 DF10KB (Transmission controller system)
Details of fail-
Gear shift lever signals from 2 or more sources are input at the same time.
ure
q Controls the machine with a more important signal.
Effect of con- (1): N > D > 6 > 5 > 4 > 3 > 2 > L
troller (2): N > R
q Shifts the transmission to neutral when the signals from source (1) and (2) are input at the same time.
q Transmission may shift into higher gear speed than the one selected by gear shift lever.
Effect on the
q Transmission is held in neutral and the machine cannot start.
machine
q The gear shift lever position lamp does not match the position of the gear shift lever.
q The monitor function checks the input signal (ON, OFF) from the gear shift lever. (Code: 02211)
Related infor-
mation
Procedure turn the start switch to the on position.

2. Disconnect connector SF1, and connect T-adapter to the female side.
Between SF1 (female) (3) and ground Max. 1 V
1 Between SF1 (female) (6) and ground Max. 1 V
harness
Voltage Between SF1 (female) (7) and ground Max. 1 V
40-900 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DF10KB]

2. Disconnect connectors ATC1, ATC2, and SF1, and connect T-adapter to each female
side.
REMARK
Measure it with multimeter in continuity range. If there is no continuity, no sound is heard.
Between ATC1 (female) (6) and each pin other than pin (6) No continuity
No continuity
(15)
No continuity
(16)
No continuity
(25)
No continuity
Short circuit in wiring har- (26)
2
No continuity
(35)
No continuity
(36)
Between SF1 (female) (3) and each pin other than pin (3) No continuity
Between SF1 (female) (10) and each pin other than pin
No continuity
(10)
Between SF1 (female) (11) and each pin other than pin
No continuity
(11)
HD465-8, HD605-8 40-901


2. Put T-adapter into connector SF1.
Between SF1 (3) and
Max. 1 V
"R"
Between SF1 (4) and
Max. 1 V
"N"
Between SF1 (5) and
Max. 1 V
"D"
Between SF1 (6) and
Max. 1 V
3 Defective gear shift lever "6"
Between SF1 (7) and
ground Max. 1 V
"5"
Between SF1 (8) and
Max. 1 V
"4"
Between SF1 (9) and
Max. 1 V
"3"
Max. 1 V
"2"
Max. 1 V
"L"
40-902 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DF10KB]

REMARK
2. Put T-adapter into connector ATC1 and ATC2.
Between ATC2 (35) and
Max. 1 V
"R"
Max. 1 V
"N"
Max. 1 V
"D"
Defective transmission Between ATC2 (15) and
4
controller ground In any shift range other than
Max. 1 V
"6"
ground Max. 1 V
"5"
Max. 1 V
"4"
Max. 1 V
"3"
Max. 1 V
"2"
Max. 1 V
"L"
HD465-8, HD605-8 40-903

Circuit diagram related to transmission gear shift lever
40-904 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DGE5KX]
FAILURE CODE [DGE5KX]

Action level Failure code Ambient Air Temp Sensor Signal Out of Range
Failure
- DGE5KX (KOMTRAX Plus controller system)
Details of fail-
Voltage of signal from the ambient temperature sensor becomes 0.3 V and below, or 4.7 V and higher.
ure
Effect on the
Ambient temperature data cannot record in the KOMTRAX Plus controller.
machine
Related infor- The monitor function checks the input signal from the ambient temperature sensor. (Code: 37504 (°C), 37505
mation (V))

2. Disconnect connector VATS, and connect T-adapter to the male side.
Ambient temperature: -30 °C 46 to 57 kΩ
Defective ambient temper-
1
ature sensor Between VATS (male) (B) Ambient temperature: 0 °C 11 to 13 kΩ
Resistance
and (A) Ambient temperature: 20 °C 4.7 to 5.5 kΩ
Ambient temperature: 40 °C 2.2 to 2.6 kΩ

2. Disconnect connector KPS1, and connect T-adapter to the female side.
2
ing harness Between KPS1 (female) (45) Ambient temperature: 0 °C 11 to 13 kΩ
Resistance
and (2) Ambient temperature: 20 °C 4.7 to 5.5 kΩ

2. Disconnect connectors KPS1 and VATS, and connect T-adapter to each female side.
3
ness Between KPS1 (female) (45) and VATS (female) (A) Max. 1 Ω
Resistance
Between KPS1 (female) (2) and VATS (female) (B) Max. 1 Ω

Ground fault in wiring har- 2. Disconnect connectors KPS1 and VATS, and connect T-adapter to either female side.
4
ness Between ground and KPS1 (female) (45) or VATS (female)
(A)

Hot short circuit in wiring 2. Put a T-adapter into connector KPS1 or VATS.
5
harness
Voltage Between KPS1 (45) and (2), or between VATS (B) and (A) Max. 4.7 V
6
HD465-8, HD605-8 40-905

FAILURE CODE [DGE5KX] 40 TROUBLESHOOTING
Circuit diagram related to ambient temperature sensor
40-906 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DGF1KX]
FAILURE CODE [DGF1KX]

Action level Failure code T/M Oil Temperature Sensor Input Signal Out of Range
Failure
L03 DGF1KX (Transmission controller system)
These are found:

- Voltage of the signal circuit of the transmission oil temperature sensor is 0.97 V (150 °C and higher), or
Details of fail-
- Only transmission oil temperature is low (transmission oil temperature sensor signal circuit voltage is 4.56 V
ure
and higher (15 °C and lower), and
- Torque converter and brake oil temperature sensor voltage is 3.7 V and below (55 °C and higher).
Effect of con-
Controls clutch oil pressure while it recognizes oil temperature as a set high temperature.
troller
Effect on the
Gear shift shocks will be larger.
machine
q If failure code [DGR2KB] or [DGT1KX] is also shown, troubleshoot for it first.
q The monitor function checks the input signal from the transmission oil temperature sensor. (Code: 32500
Related infor- (°C), 32501 (V))
mation q Make sure that the machine goes back to normal condition after repair work. Then perform the initial learn-
ing of the transmission controller. Refer to TEST AND ADJUST, "SET AND ADJUST EACH EQUIP-
MENT".

2. Disconnect connector T/M, T, and connect T-adapter to the male side.
38.1 to 47.8
kΩ
30.1 to 40.0
Between T/M, T (male) (1) Oil temperature: 30 °C
Defective transmission oil kΩ
1 and (2) (Oil temperature
temperature sensor
Resistance sensor heat properties) Oil temperature: 80 °C 6.1 to 7.0 kΩ
Between ground and T/M, T
(male) (1) or (2)
Open circuit in wiring har- 2. Disconnect connectors ATC1 and T/M,T, and connect T-adapter to each female side.
2
ness Between ATC1 (female) (21) and T/M,T (female) (2) Max. 1 Ω
Resistance
Between ATC1 (female) (3) and T/M,T (female) (1) Max. 1 Ω

Ground fault in wiring har- 2. Disconnect connectors ATC1 and T/M,T, and connect T-adapter to either female side.
3
ness
Between ground and ATC1 (female) (3) or T/M,T (female)
(1)

Short circuit in wiring har- 2. Disconnect connectors ATC1 and T/M,T, and connect T-adapter to female side of
4
ness ATC1.
HD465-8, HD605-8 40-907

FAILURE CODE [DGF1KX] 40 TROUBLESHOOTING

2. Insert T-adapter into connector T/M,T.
harness
Oil temperature: 25 °C or
Voltage Between T/M,T (1) and (2) Max. 4.5 V
higher
6
Circuit diagram related to transmission oil temperature sensor
40-908 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DGR2KB]
FAILURE CODE [DGR2KB]

Action level Failure code Retarder Oil Temperature Sensor Ground Fault (Rear)
Failure
L01 DGR2KB (Retarder and hoist controller system)
Details of fail-
Signal voltage of the retarder oil temperature sensor circuit becomes 0.97 V and lower.
ure
Effect of con-
None in particular
troller
Effect on the
Oil temperature gauge shows 150 °C or higher and it becomes inoperable.
machine
q The monitor function checks the input signal from the retarder oil temperature sensor. (Code: 30215 (°C),
Related infor- 30212 (V))

2. Disconnect connector RTR, and connect T-adapter to the male side.
38.1 to 47.8
kΩ
31.0 to 40.0
Defective retarder oil pres- Between RTR (male) (1) and Oil temperature: 30 °C
kΩ
sure sensor (rear)
Between ground and RTR
(male) (1) or (2)

Ground fault in wiring har- 2. Disconnect connector BRC1, and connect T-adapter to the female side.
2
ness
Resistance Between BRC1 (female) (20) and ground Min. 1 MΩ
3
HD465-8, HD605-8 40-909

FAILURE CODE [DGR2KB] 40 TROUBLESHOOTING
Circuit diagram related to retarder oil temperature sensor
40-910 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DGR6KB]
FAILURE CODE [DGR6KB]

Action level Failure code Steering Oil Temperature Sensor Ground Fault
Failure
L01 DGR6KB (Retarder and hoist controller system)
Details of fail-
Signal voltage of the retarder oil temperature sensor circuit becomes 0.97 V and lower.
ure
Effect of con-
None in particular
troller
Effect on the
Oil temperature gauge shows 150 °C or higher and it becomes inoperable.
machine
q The monitor function checks the input signal from the steering oil temperature sensor. (Code: 32701 (°C),

38.1 to 47.8
kΩ
31.0 to 40.0
Defective steering oil tem- Between STR (male) (1) and Oil temperature: 30 °C
kΩ
perature sensor
(male) (1) or (2)

Ground fault in wiring har- 2. Disconnect connector BRC1, and connect T-adapter to the female side.
2
ness
Resistance Between BRC1 (female) (9) and ground Min. 1 MΩ
3
HD465-8, HD605-8 40-911

FAILURE CODE [DGR6L8] 40 TROUBLESHOOTING
FAILURE CODE [DGR6L8]

Action level Failure code Steering Oil Temperature Sensor Open Circuit or Hot Short Circuit
Failure
L01 DGR6L8 (Retarder and hoist controller system)
Details of fail- The signal circuit in the steering oil temperature sensor is 4.56 V and higher. The torque converter oil temper-
ure ature is 55 °C and higher. The signal circuit in the retarder oil temperature sensor (rear) is 3.7 V and lower.
Effect of con-
None in particular
troller
Effect on the
If the machine is used as it is, flow rate of the brake cooled oil decreases, and the engine can get too hot.
machine
q The monitor function checks the input signal from the steering oil temperature sensor. (Code: 32701 (°C),

38.1 to 47.8
kΩ
31.0 to 40.0
Defective steering oil tem- Between STR (male) (1) and Oil temperature: 30 °C
kΩ
perature sensor
(male) (1) or (2)

2. Disconnect connectors BRC1 and STR, and connect T-adapter to each female side.
2
ness Between BRC1 (female) (9) and STR (female) (1) Max. 1 Ω
Resistance
Between BRC1 (female) (21) and STR (female) (2) Max. 1 Ω

Hot short circuit in wiring 2. Put T-adapter into connector BRC1 or STR.
harness
Voltage Between BRC1 (9) and (21), or between STR (1) and (2) Max. 4.7 V
4
40-912 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DGR6L8]
HD465-8, HD605-8 40-913

FAILURE CODE [DGT1KX] 40 TROUBLESHOOTING
FAILURE CODE [DGT1KX]

Action level Failure code T/C Oil Temperature Sensor Input Signal Out of Range
Failure
L01 DGT1KX (Transmission controller system)
The signal voltage of transmission valve oil temperature is 3.7 V and below (55 °C and lower). Then the signal
Details of fail-
circuit voltage of torque converter oil temperature sensor is 0.97 V and below (150 °C and higher) or, 4.56 V
ure
and higher (15 °C and lower).
Effect of con-
None in particular
troller
Effect on the q Torque converter oil temperature gauge is not shown.
machine q Automatic idle stop function does not work.
k Before you perform this procedure, raise the body to the maximum height. Make sure to set the
hoist lever to "HOLD". Set the lock knob to the LOCK position, and engage the body pivot pin.
Related infor-
mation q The monitor function checks the torque converter oil temperature. (Code: 30100 (°C), 30101 (V))

2. Disconnect connector T/C, T, and connect T-adapter to the male side.
38.1 to 47.8
kΩ
30.1 to 40.0
Between T/C, T (male) (1) Oil temperature: 30 °C
Defective torque converter kΩ
1 and (2) (Oil temperature
oil temperature sensor
Resistance sensor heat properties) Oil temperature: 80 °C 6.1 to 7.0 kΩ
Between ground and T/C, T
(male) (1) or (2)

2. Disconnect connectors ATC1 and T/C,T, and connect T-adapter to each female side.
2
ness Between ATC1 (female) (21) and T/C,T (female) (2) Max. 1 Ω
Resistance
Between ATC1 (female) (9) and T/C,T (female) (1) Max. 1 Ω

Ground fault in wiring har- 2. Disconnect connectors ATC1 and T/C,T, and connect T-adapter to either female side.
3
ness Between ground and ATC1 (female) (9) or T/C,T (female)
(1)

Short circuit in wiring har- 2. Disconnect connectors ATC1 and T/C,T, and connect T-adapter to female side of
4
ness ATC1.

2. Insert T-adapter into connector T/C,T.
Hot short circuit in wiring 3. Turn the starting switch to ON position.
5
harness
Oil temperature: 25 °C or
Voltage Between T/C,T (1) and (2) Max. 4.5 V
higher
6
40-914 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DGT1KX]
Circuit diagram related to torque converter oil temperature sensor
HD465-8, HD605-8 40-915

FAILURE CODE [DGT4KA] 40 TROUBLESHOOTING
FAILURE CODE [DGT4KA]

Action level Failure code Exhaust Temperature Sensor Open Circuit Fault
Failure
- DGT4KA (KOMTRAX Plus controller system)
Details of fail-
Signal voltage from the exhaust temperature sensor becomes 0.5 V and lower.
ure
Effect on the
Exhaust temperature data is not recorded in the KOMTRAX Plus controller.
machine
q If failure code [DBV6KB] is shown, first troubleshoot for [DBV6KB].
Related infor-
q The monitor function checks the input signal from the exhaust temperature sensor. (Code: 42602 (°C),
mation
42603 (V))

2. Disconnect connector KPS1, KPS2, HM23A, HM22A, and HM21A, and connect
T-adapter to the female side of KPS1, KPS2, HM23A, and HM21A.
3. Disconnect connector HM22A, and connect T-adapter to the male side.
Open circuit in wiring har- Between HM23A (female) (A) and KPS2 (female) (49) Max. 1 Ω
1
ness Between HM23A (female) (B) and KPS1 (female) (42) Max. 1 Ω
Resistance Between HM23A (female) (C) and KPS1 (female) (2) Max. 1 Ω
Between HM21A (female) (1) and HM22A (male) (1) Max. 1 Ω

2. Disconnect connectors KPS1, HM23A, HM22A, and HM21A and connect T-adapter
Ground fault in wiring har- to either female side.
2
ness
Between HM21A (female) (1) and ground Min. 1 MΩ
Resistance
Between HM23A (female) (A) and ground Min. 1 MΩ

2. Put a T-adapter into connector HM23A.
Exhaust temperature: 50 to
1.2 to 1.4 V
100 °C
Defective exhaust gas tem- Exhaust temperature: 300 to

3 2.2 to 2.6 V
perature sensor amplifier 400 °C
Between HM23A (B) and (C)
Voltage Exhaust temperature: 500 to
3.1 to 3.5 V
600 °C
3.9 to 4.3 V
800 °C
Between HM23A (A) and (C) All temperature range 20 to 30 V
40-916 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DGT4KA]

REMARK
A problem is difficult to find because the output voltage from the sensor is a value in mV.
Defective exhaust temper- 1.2 to 3.3 mV
4 100 °C
ature sensor
Exhaust temperature: 300 to 11.4 to 15.6
400 °C mV
Voltage Between HM21A (1) and (2)
600 °C mV
800 °C mV
5
Circuit diagram related to exhaust temperature sensor electric system
HD465-8, HD605-8 40-917

FAILURE CODE [DGT4KB] 40 TROUBLESHOOTING
FAILURE CODE [DGT4KB]

Action level Failure code Exhaust Temperature Sensor Ground Fault
Failure
- DGT4KB (KOMTRAX Plus controller system)
Details of fail-
Voltage of signal from the exhaust temperature sensor becomes 4.9 V and higher.
ure
Effect on the
machine
Related infor-
42603 (V))
mation
q This failure code is applied to a machine for serial number less than 30112.

2. Disconnect connector HM21A, and connect a T-adapter to the female side.
Open circuit in wiring har- 3. Disconnect connector HM22A, and connect a T-adapter to the male side.
1
ness
Resistance

Hot short circuit in wiring 2. Disconnect connector HM23A, and connect T-adapter to female side.
harness
Voltage Between HM23A (female) (B) and ground Max. 1 V

1.2 to 1.4 V
100 °C

3 2.2 to 2.6 V
3.1 to 3.5 V
600 °C
3.9 to 4.3 V
800 °C

REMARK
4 100 °C
ature sensor
400 °C mV
600 °C mV
800 °C mV
40-918 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DGT4KB]

5
HD465-8, HD605-8 40-919

FAILURE CODE [DGT4KY] 40 TROUBLESHOOTING
FAILURE CODE [DGT4KY]

Action level Failure code Exhaust Temperature Sensor Hot Short
Failure
- DGT4KY (KOMTRAX Plus controller system)
Details of fail-
Voltage of signal from the exhaust temperature sensor becomes 4.9 V and higher.
ure
Effect on the
machine
Related infor-
42603 (V))
mation
q This failure code is applied to a machine for serial number more than 30113.

2. Disconnect connector HM21A, and connect a T-adapter to the female side.
Open circuit in wiring har- 3. Disconnect connector HM22A, and connect a T-adapter to the male side.
1
ness
Resistance

Hot short circuit in wiring 2. Disconnect connector HM23A, and connect T-adapter to female side.
harness
Voltage Between HM23A (female) (B) and ground Max. 1 V

1.2 to 1.4 V
100 °C

3 2.2 to 2.6 V
3.1 to 3.5 V
600 °C
3.9 to 4.3 V
800 °C

REMARK
4 100 °C
ature sensor
400 °C mV
600 °C mV
800 °C mV
40-920 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DGT4KY]

5
HD465-8, HD605-8 40-921

FAILURE CODE [DHA4KA] 40 TROUBLESHOOTING
FAILURE CODE [DHA4KA]

Action level Failure code Air Cleaner Clogging Sensor Open Circuit
Failure
L01 DHA4KA (Machine monitor system)
Machine monitor finds the air cleaner blockage sensor open circuit (sensor contacts "OPEN"). Blockage
Details of fail-
found when the signal voltage of the air cleaner blockage switch is not 1 V or lower, when you turn the start
ure
switch is to ON.
Effect of con-
None in particular
troller
If the machine
is used as is,
blockage in
the air
cleaner is not If the machine is used as is, blockage in the air cleaner is not sensed correctly, and the engine is likely dam-
sensed cor- aged.
rectly, and the
engine is
likely dam-
aged.
q Input voltage from the air cleaner clogging sensor can be checked by the monitoring function. (Code:

Examine if the air cleaner is clogged. If it is clogged, clean or replace it.
1 Air Cleaner Clog Dust gauge does not show red. Air cleaner is normal.
Dust gauge shows red. Air Cleaner Clogged

2. Disconnect connector FP01, and connect a T-adapter to the male side.
3. Turn the start switch to the on position.
REMARK
Air cleaner intake obstruction
Defective air cleaner block-
2 *1: -3430 Pa or less {-350 mmH2O or less}
age sensor
*2: -7470±490 Pa {-762±50 mmH2O}
When air cleaner is normal
Max. 1 Ω
Between FR01 (male) (1) *1
Resistance
and (2) When air cleaner is clogged
Min. 1 MΩ
*2

2. Disconnect connectors MCM1 and FR01, and connect T-adapter to each female side.
3
ness Between MCM1 (female) (53) and FR01 (female) (2) Max. 1 Ω
Resistance
Between MCM1 (female) (13) and FR01 (female) (1) Max. 1 Ω

2. Put a T-adapter into connector MCM1.
Defective monitor control- Air cleaner is normal. Max. 1 V
ler Voltage
(13) Air Cleaner clogs 6 to 12 V
40-922 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DHA4KA]
Circuit diagram related to the hydraulic oil filter blockage
HD465-8, HD605-8 40-923

FAILURE CODE [DHAAMA] 40 TROUBLESHOOTING
FAILURE CODE [DHAAMA]

Action level Failure code KDPF Differential Pressure Sensor Frozen
Failure
- DHAAMA (Engine controller system)
Details of fail- Signal voltage from the KDPF differential pressure sensor does not show a correct value when ambient tem-
ure perature is low because the sensor is frozen. (Signal voltage is in "normal" or "operation" range.)
Effect of con-
Normal operation
troller
Effect on the
None in particular
machine
q If failure code [CA1883] is shown, or failure code is shown on the Problem record screen, first troubleshoot
for code [CA1883].
Related infor- q The cause of this failure code is eliminated after the freeze solution. Troubleshooting is not required.
mation q The ambient temperature is not low enough to freeze the sensor when this failure code is shown in the
Problem record. Then, identify the cause with the procedure that follows.
q To access the KDPF differential pressure sensor, and the wiring harness and pipe, refer to Chapter 50,
DISASSEMBLE AND ASSEMBLE, ”REMOVE AND INSTALL KDPF ASSEMBLY" and "DISASSEMBLE
AND ASSEMBLE OF KDPF ASSEMBLY".

Defective intake air tem- If there is any failure, examine the installation of the intake air temperature sensor, and
1
perature sensor install it again correctly (if necessary).
If this failure code remains shown when the ambient temperature is high, the engine con-
troller is defective. (Since this is an internal problem, you cannot troubleshoot.)
40-924 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DHABMA]
FAILURE CODE [DHABMA]

Action level Failure code KDPF Differential Pressure Sensor Frozen_2
Failure
- DHABMA (Engine controller system)
Details of fail- Signal voltage from the KDPF differential pressure sensor does not show a correct value when ambient tem-
ure perature is low because the sensor is frozen. (Signal voltage is in "normal" or "operation" range.)
Effect of con-
Normal operation
troller
Effect on the
None in particular
machine
q If failure code [CB1883] is showed, or the failure code is shown on the Problem record screen, first trou-
Related infor- bleshoot for code [CB1883].
mation q The cause of this failure code is eliminated after the freeze solution. Troubleshooting is not required.
q The ambient temperature is not low enough to freeze the sensor when this failure code is shown on the
problem record. Then, identify the cause with this procedure.

1
If this failure code remains displayed when the ambient temperature is high, the engine
HD465-8, HD605-8 40-925

FAILURE CODE [DHACMA] 40 TROUBLESHOOTING
FAILURE CODE [DHACMA]

Action level Failure code KDPF Outlet Pressure Sensor Frozen
Failure
- DHACMA (Engine controller system)
Details of fail- Signal voltage from the KDPF output pressure sensor does not show a correct value when ambient tempera-
ure ture is low because of its frozen sensor. (Signal voltage is in "normal" or "operation" range.)
Effect of con- Lowers the regeneration temperature during regeneration, lower than that of normal regeneration. (Tempera-
troller ture is lowered as low as when failure code [AQ00N4] is shown.)
Effect on the
None in particular
machine
bleshoot for code [CB1883].
Related infor- q The cause of this failure code is eliminated after the freeze solution. Troubleshooting is not required.
mation q The ambient temperature is not at the freeze point when this failure code shows on the problem record.
Then, identify the cause with the procedures below.
q To access the KDPF differential pressure sensor, and the wiring harness and pipe, refer to Chapter 50,
DISASSEMBLE AND ASSEMBLE, ”REMOVE AND INSTALL KDPF ASSEMBLY" and "DISASSEMBLE
AND ASSEMBLE OF KDPF ASSEMBLY".

1
40-926 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DHADMA]
FAILURE CODE [DHADMA]

Action level Failure code KDPF Outlet Pressure Sensor Frozen_2
Failure
- DHADMA (Engine controller system)
Details of fail- Signal voltage from the KDPF output pressure sensor does not show a correct value when ambient tempera-
ure ture is low because of its frozen sensor. (Signal voltage is in "normal" or "operation" range.)
Effect of con- Lowers the regeneration temperature during regeneration lower than that of normal regeneration. (Tempera-
troller ture is lowered as low as when failure code [AQ00N4] is shown.)
Effect on the
None in particular
machine
Related infor- bleshoot for code [CB1883].
mation q The cause of this failure code is eliminated after solution of the freeze. Troubleshooting is not required.
q The ambient temperature is not low enough to freeze the sensor when this failure code is shown on the
problem record. Then identify the cause with the procedure that follows.

1
HD465-8, HD605-8 40-927

FAILURE CODE [DHP4KY] 40 TROUBLESHOOTING
FAILURE CODE [DHP4KY]

Action level Failure code Suspension Pressure Sensor Hot Short Circuit (Front Right)
Failure
L01 DHP4KY (KOMTRAX Plus controller system)
Details of fail-
Voltage of signal circuit of the suspension pressure sensor (front right) becomes 4.9 V and higher.
ure
Effect of con-
None in particular
troller
Effect on the
Load weight capacity is not shown correctly.
machine
q The monitor function checks the input voltage from the suspension pressure sensor (front right). (Code:
Procedure: Turn the start switch to ON. (Maintain the ON state for 5 minutes or longer.)

Defective sensor power 2. Disconnect connector SUFR, and connect T-adapter to the female side.
supply system
Voltage Between SUFR (female) (B) and (A) Approx. 24 V

2. Disconnect connector SUFR.
Defective suspension pres- 3. Turn the start switch to the ON position.
2
sure sensor (front right)
If the failure code changes from [DHP4KY] to [DHP4KZ], the suspension pressure sensor
(front right) is defective.

2. Disconnect connector SUFR.
Hot short circuit in wiring 3. Insert T-adapter into connector KPS1, or connect T-adapter to the female side of
3 connector SUFR.
harness
Voltage Between ground and KPS1 (15) or SUFR (female) (C) Max. 1 V

2. Put a T-adapter into connector KP1 and KPS2.
Defective KOMTRAX Plus Between KPS2 (49) and KPS1 (1) Approx. 24 V
4
controller Voltage
Between KPS1 (1) and (15) 1.0 to 5.0 V
If there is no failure with the checks above, KOMTRAX Plus controller is defective. (Since
40-928 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DHP4KY]
Circuit diagram related to suspension pressure sensor (front right)
HD465-8, HD605-8 40-929

FAILURE CODE [DHP4KZ] 40 TROUBLESHOOTING
FAILURE CODE [DHP4KZ]

Action level Failure code Suspension Pressure Sensor Open Circuit or Ground Fault (Front Right)
Failure
L01 DHP4KZ (KOMTRAX Plus controller system)
Details of fail-
Voltage of signal circuit of the suspension pressure sensor (front right) becomes 0.3 V and lower.
ure
Effect of con-
None in particular
troller
Effect on the
machine
q If failure code [DBV6KB] is shown, first troubleshoot for code [DBV6KB].
q The monitor function checks the input voltage from the suspension pressure sensor (front right). (Code:
Related infor-
32810)
mation

Defective sensor power 2. Disconnect connector SUFR, and connect a T-adapter to the female side.
supply system
Voltage Between SUFR (female) (B) and (A) Approx. 24 V

2. Disconnect connectors SUFR, KPS1, and KPS2, and connect T-adapter to each
female side.
Between KPS1 (female) (15) and SUFR (female) (C) Max. 1 Ω
Open circuit in wiring har- If power supply voltage is normal, this check is not
2
ness required. Max. 1 Ω
Resistance Between KPS1 (female) (1) and SUFR (female) (A)
If power supply voltage is normal, this check is not
required. Max. 1 Ω
Between KPS2 (female) (49) and SUFR (female) (B)

2. Disconnect connectors SUFR, KPS1, and KPS2, and connect T-adapter to either
3
ness
Between ground and KPS1 (female) (15) or SUFR (female)
(C)

Defective suspension pres- 2. Put a T-adapter into connector SUFR.
sure sensor (front right)
Voltage Between SUFR (C) and (A) 1.0 to 5.0 V

5
controller Voltage
40-930 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DHP4KZ]
Circuit diagram related to suspension pressure sensor (front right)
HD465-8, HD605-8 40-931


Action level Failure code Suspension Pressure Sensor Hot Short Circuit (Front Left)
Failure
Details of fail-
Voltage of signal circuit of the suspension pressure sensor (front left) becomes 4.9 V and higher.
ure
Effect of con-
None in particular
troller
Effect on the
machine
q The monitor function checks the input voltage from the suspension pressure sensor (front left). (Code:
Procedure turn the start switch to the ON position. (Maintain the ON state for 5 minutes or longer.)

Defective sensor power 2. Disconnect connector SUFL, and connect a T-adapter to the female side.
supply system
Voltage Between SUFL (female) (B) and (A) Approx. 24 V

2. Disconnect connector SUFL.
Suspension Pressure Sen- 3. Turn the start switch to the ON position.
2
sor (front left)
(front left) is defective.

2. Disconnect connector SUFL.
Hot short circuit in wiring 3. Put a T-adapter into connector KPS1, or connect a T-adapter to female side of
3 connector SUFL.
harness
Voltage Between ground and KPS1 (21) or SUFL (female) (C) Max. 1 V

4
controller Voltage
40-932 HD465-8, HD605-8

Circuit diagram related to suspension pressure sensor (front left)
HD465-8, HD605-8 40-933


Action level Failure code Suspension Pressure Sensor Open Circuit or Ground Fault (Front Left)
Failure
Details of fail-
Voltage of signal circuit of the suspension pressure sensor (front left) becomes 0.3 V and lower.
ure
Effect of con-
None in particular
troller
Effect on the
machine
q If failure code [DBV6KB] is shown, first troubleshoot for code [DBV6KB].
q The monitor function checks the input voltage from the suspension pressure sensor (front left). (Code:
Related infor-
32809)
mation

Defective sensor power 2. Disconnect connector SUFL, and connect a T-adapter to the female side.
supply system
Voltage Between SUFL (female) (B) and (A) Approx. 24 V

2. Disconnect connectors SUFL, KPS1, and KPS2, and connect T-adapter to each
female side.
Between KPS1 (female) (21) and SUFL (female) (C) Max. 1 Ω
2
Resistance Between KPS1 (female) (1) and SUFL (female) (A)
required. Max. 1 Ω
Between KPS2 (female) (49) and SUFL (female) (B)

2. Disconnect connectors SUFL, KPS1, and KPS2, and connect T-adapter to either
3
ness
Between ground and KPS1 (female) (21) or SUFL (female)
(C)

Suspension Pressure Sen- 2. Put a T-adapter into connector SUFL.
sor (front left)
Voltage Between SUFL (C) and (A) 1.0 to 5.0 V

5
controller Voltage
If no failure is found by the previous checks, KOMTRAX Plus controller is defective.
40-934 HD465-8, HD605-8

HD465-8, HD605-8 40-935

FAILURE CODE [DHP6KA] 40 TROUBLESHOOTING
FAILURE CODE [DHP6KA]

Action level Failure code Suspension Pressure Sensor Signal Out of Range (Rear Right)
Failure (Retarder and hoist controller system)
L01 DHP6KA (When ARSC is not set, or ARSC system is set in "OFF")
Details of fail- Voltage of signal circuit of the suspension pressure sensor (rear right) becomes 0.5 V and below or 4.7 V and
ure higher.
Effect of con- q Fixes the selection value whether the machine is empty or loaded to "LOAD".
troller q Cancel automatic suspension control.
Effect on the q The selection value whether the machine is empty or loaded is "LOAD".
Related infor- Suspension pressure signal (rear right) can be checked by the monitoring function. (Code: 32816(MPa),
mation 32817(V))

If failure code [DBV6KB] is shown, troubleshoot for it first.

Defective sensor power
1 2. Disconnect connector SURR, and connect T-adapter to female side.
supply system
Voltage Between SURR (female) (B) and (A) 20 to 30 V

2. Disconnect connectors BRC1, SURR, KPS1, and KPS2, and connect T-adapter to
each female side.
Between BRC1 (female) (12) and SURR (female) (C) Max. 1 Ω
2
Resistance Between KPS1 (female) (1) and SURR (female) (A)
required. Max. 1 Ω
Between KPS2 (female) (49) and SURR (female) (B)

2. Disconnect connectors BRC1, SURR, KPS1, and KPS2.
Ground fault in wiring har- 3. Connect T-adapter to the female side of BRC1 or SURR.
3
ness
Between ground and BRC1 (female) (12) or SURR
(female) (C)

Hot short circuit in wiring 2. Disconnect connector SURR, and connect T-adapter to the female side.
harness
Voltage Between SURR (female) (C) and (A) Max. 1 V

Defective suspension pres- 2. Insert T-adapter into connector SURR.
sure sensor (RR)
Voltage Between SURR (C) and (A) 0.5 to 4.7 V

Defective KOMTRAX Plus 2. Put a T-adapter into connector KPS1.
controller
Voltage Between KPS1 (1) and (23) 20 to 30 V
40-936 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DHP6KA]

7
hoist controller Voltage Between BRC1 (12) and ground 0.5 to 4.7 V
Circuit diagram related to suspension pressure sensor (rear right)
HD465-8, HD605-8 40-937

FAILURE CODE [DHP6KX] 40 TROUBLESHOOTING
FAILURE CODE [DHP6KX]

Action level Failure code Suspension Pressure Sensor Signal Out of Range (Rear Right)
L03 DHP6KX (When ARSC is set, and ARSC system is set in "ON".)
Details of fail- Voltage of signal circuit of the suspension pressure sensor (rear right) becomes 0.5 V and below or 4.7 V and
ure above.
q Releases the brake gradually when ARSC operates.
Effect of con-
q Fixes the selection value whether the machine is empty or loaded to "LOAD".
troller
q Cancel automatic suspension control.
q ARSC does not work.
Effect on the
q The selection value whether the machine is empty or loaded is "LOAD".
machine
Related infor- Suspension pressure sensor (rear right) can be checked by the monitoring function. (Code: 32816 (MPa),
mation 32817 (V))


1 2. Disconnect connector SURR, and connect T-adapter to female side.
supply system
Voltage Between SURR (female) (B) and (A) 20 to 30 V

2. Disconnect connectors BRC1, SURR, KPS1, and KPS2, and connect T-adapter to
each female side.
Between BRC1 (female) (12) and SURR (female) (C) Max. 1 Ω
2 If power supply voltage is normal, this check is not
required. Max. 1 Ω

Ground fault in wiring har- 3. Connect T-adapter to the female side of BRC1 or SURR.
3
ness
Between ground and BRC1 (female) (12) or SURR
(female) (C)

Hot short circuit in wiring 2. Disconnect connector SURR, and connect T-adapter to the female side.
harness
Voltage Between SURR (female) (C) and (A) Max. 1 V

Defective suspension pres- 2. Insert T-adapter into connector SURR.
sure sensor (RR)

controller
40-938 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DHP6KX]

7
HD465-8, HD605-8 40-939


Action level Failure code Suspension Pressure Sensor Hot Short Circuit (Rear Right)
Failure
Details of fail-
Voltage of signal circuit of the suspension pressure sensor (rear right) becomes 4.9 V and higher.
ure
Effect of con-
None in particular
troller
Effect on the
machine
q The monitor function checks the input voltage from the suspension pressure sensor (rear right). (Code:

2. Disconnect connector SURR, and connect a T-adapter to the female side.
Defective sensor power 3. Turn the start switch to the ON position.
1
supply system
Battery Volt-
Between SURR (female) (B) and (A) Approx. 24 V
age

2. Disconnect connector SURR.
Suspension pressure sen- 3. Turn the start switch to the ON position.
2
sor (rear right)
(rear right) is defective.

2. Disconnect connector SURR.
3 connector SUFL.
harness
Voltage Between ground and KPS1 (23) or SURR (female) (C) Max. 1 V

5
controller Voltage
40-940 HD465-8, HD605-8

HD465-8, HD605-8 40-941


Action level Failure code Suspension Pressure Sensor Open Circuit or Ground Fault (Rear Right)
Failure
Details of fail-
Voltage of signal circuit of the suspension pressure sensor (rear right) becomes 0.3 V and lower.
ure
Effect of con-
None in particular
troller
Effect on the
machine
q If failure code [DBV6KB] is shown, first, troubleshoot for code [DBV6KB].
q The monitor function checks the input voltage from the suspension pressure sensor (rear right). (Code:
Related infor-
32812)
mation

Defective sensor power 2. Disconnect connector SURR, and connect T-adapter to the female side.
1 3. Turn the start switch to the on position.
supply system
Voltage Between SURR (female) (B) and (A) Approx. 24 V

2. Disconnect connectors SURR, KPS1, and KPS2, and connect T-adapter to each
female side.
Between KPS1 (female) (23) and SURR (female) (C) Max. 1 Ω
2
required. Max. 1 Ω

2. Disconnect connectors SURR, KPS1, and KPS2, and connect T-adapter to either
3
ness
Between ground and KPS1 (female) (23) or SURR (female)
(C)

Suspension pressure sen- 2. Put a T-adapter into connector SURR.
sor (rear right)

5
controller Voltage
40-942 HD465-8, HD605-8

Circuit diagram related to the suspension pressure sensor (rear right)
HD465-8, HD605-8 40-943

FAILURE CODE [DHP7KA] 40 TROUBLESHOOTING
FAILURE CODE [DHP7KA]

Action level Failure code Suspension Pressure Sensor Signal Out of Range (Rear Left)
L01 DHP7KA (When ARSC is not set, or ARSC system is set in "OFF")
Details of fail- Voltage of signal circuit of the suspension pressure sensor (rear left) becomes 0.5 V and below or 4.7 V and
ure above.
Effect of con- q Fixes the selection value whether the machine is empty or loaded to "LOAD".
troller q Cancel automatic suspension control.
Effect on the q The selection value whether the machine is empty or loaded is "LOAD".
Related infor- Suspension pressure sensor (rear left) can be checked by the monitoring function. (Code: 32814 (MPa),
mation 32815 (V))


1 2. Disconnect connector SURL, and connect T-adapter to the female side.
supply system
Voltage Between SURL (female) (B) and (A) 20 to 30 V

2. Disconnect connectors BRC1, SURL, KPS1, and KPS2, and connect T-adapter to
each female side.
Between BRC1 (female) (14) and SURL (female) (C) Max. 1 Ω
2
Resistance Between KPS1 (female) (1) and SURL (female) (A)
required. Max. 1 Ω
Between KPS2 (female) (49) and SURL (female) (B)

Ground fault in wiring har- 3. Connect T-adapter to the female side of BRC1 or SURL.
3
ness
Between ground and BRC1 (female) (14) or SURL (female)
(C)

Hot short circuit in wiring 2. Disconnect connector SURL, and connect T-adapter to the female side.
harness
Voltage Between SURL (female) (C) and (A) Max. 1 V

Defective suspension pres- 2. Put a T-adapter into connector SURL.
sure sensor (RL)
Voltage Between SURL (C) and (A) 0.5 to 4.7 V

controller
40-944 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DHP7KA]

7
HD465-8, HD605-8 40-945

FAILURE CODE [DHP7KX] 40 TROUBLESHOOTING
FAILURE CODE [DHP7KX]

Action level Failure code Suspension Pressure Sensor Signal Out of Range (Rear Left)
L03 DHP7KX (When ARSC is set, and ARSC system is set in "ON".)
Details of fail- Voltage of signal circuit of the suspension pressure sensor (rear left) becomes 0.5 V and below or 4.7 V and
ure higher.
q Releases the brake gradually when ARSC operates.
Effect of con-
q Fixes the selection value whether the machine is empty or loaded to "LOAD".
troller
q Cancel automatic suspension control.
q ARSC does not work.
Effect on the
q The selection value whether the machine is empty or loaded is "LOAD".
machine
Related infor- Suspension pressure sensor (rear left) can be checked by the monitoring function. (Code: 32814 (MPa),
mation 32815 (V))


1 2. Disconnect connector SURL, and connect T-adapter to the female side.
supply system
Voltage Between SURL (female) (B) and (A) 20 to 30 V

2. Disconnect connectors BRC1, SURL, KPS1, and KPS2, and connect T-adapter to
each female side.
Between BRC1 (female) (14) and SURL (female) (C) Max. 1 Ω
required. Max. 1 Ω

Ground fault in wiring har- 3. Connect T-adapter to the female side of BRC1 or SURL.
3
ness
Between ground and BRC1 (female) (14) or SURL (female)
(C)

Hot short circuit in wiring 2. Disconnect connector SURL, and connect T-adapter to the female side.
harness
Voltage Between SURL (female) (C) and (A) Max. 1 V

sure sensor (RL)

controller
40-946 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DHP7KX]

7
HD465-8, HD605-8 40-947


Action level Failure code Suspension Pressure Sensor Hot Short Circuit (Rear Left)
Failure
Details of fail-
Voltage of signal circuit of the suspension pressure sensor (rear left) becomes 4.9 V and higher.
ure
Effect of con-
None in particular
troller
Effect on the
machine
q The monitor function checks the input voltage from the suspension pressure sensor (rear left). (Code:

Defective sensor power 2. Disconnect connector SURL, and connect a T-adapter to the female side.
supply system
Voltage Between SURL (female) (B) and (A) Approx. 24 V

2. Disconnect connector SURL.
Defective suspension pres- 3. Turn the start switch to the ON position.
2
sure sensor (rear left)
(rear left) is defective.

2. Disconnect connector SURL.
3 connector SURL.
harness
Voltage Between ground and KPS1 (22) or SURL (female) (C) Max. 1 V

4
controller Voltage
40-948 HD465-8, HD605-8

Circuit diagram related to the suspension pressure sensor (rear left)
HD465-8, HD605-8 40-949


Action level Failure code Suspension Pressure Sensor Open Circuit or Ground Fault (Rear Left)
Failure
Details of fail-
Voltage of signal circuit of the suspension pressure sensor (rear left) becomes 0.3 V and lower.
ure
Effect of con-
None in particular
troller
Effect on the
machine
q If failure code [DBV6KB] is shown, first, troubleshoot for code [DBV6KB].
q The monitor function checks the input voltage from the suspension pressure sensor (rear left). (Code:
Related infor-
32813)
mation

Defective sensor power 2. Disconnect connector SURL, and connect T-adapter to female side.
1 3. Turn the start switch to the on position.
supply system
Voltage Between SURL (female) (B) and (A) Approx. 24 V

2. Disconnect connectors SURL, KPS1, and KPS2, and connect T-adapter to each
female side.
Between KPS1 (female) (22) and SURL (female) (C) Max. 1 Ω
2
required. Max. 1 Ω

2. Disconnect connectors SURL, KPS1, and KPS2, and connect T-adapter to either
3
ness
Between ground and KPS1 (female) (22) or SURL (female)
(C)

sure sensor (rear left)

5
controller Voltage
40-950 HD465-8, HD605-8

Circuit diagram related to suspension pressure sensor (rear left)
HD465-8, HD605-8 40-951

FAILURE CODE [DHQ2KX] 40 TROUBLESHOOTING
FAILURE CODE [DHQ2KX]

Action level Failure code Main Flow Select Valve Pressure Sensor Input Signal Out of Range
Failure
L01 DHQ2KX (Transmission controller system)
Details of fail- Voltage of signal circuit of the primary flow selector solenoid operation pressure sensor becomes 0.3 V and
ure below or 4.7 V and higher.
troller q No longer operates the primary flow variable solenoid.
Effect on the Primary flow selector solenoid and primary pressure variable solenoid do not function and fuel consumption
hoist lever to "HOLD". Set the lock knob to LOCK and engage the body pivot pin.
Related infor- q The monitor function examines the operation pressure of the primary flow selector valve. (Code: 07702
mation (V))

Defective sensor power 2. Disconnect connector VOL, P, and connect T-adapter to female side.
supply system
Voltage Between VOL, P (female) (3) and (1) Approx. 5 V

Open circuit in wiring har- required. Max. 1 Ω
2 Between ATC1 (female) (22) and VOL, P (female) (3)
ness
Resistance If power supply voltage is normal, this check is not
required. Max. 1 Ω
Between ATC1 (female) (21) and VOL, P (female) (1)
Between ATC1 (female) (13) and VOL, P (female) (2) Max. 1 Ω

2. Disconnect connectors ATC1, VOL, P, and M/P, PS, and connect T-adapter to the
Ground fault in wiring har- female side of VOL, P.
3
ness
Between VOL,P (female) (2) and ground Min. 1 MΩ
Resistance
Between VOL,P (female) (3) and ground Min. 1 MΩ

Hot short circuit in wiring 2. Disconnect connector VOL, P, and connect a T-adapter to the female side.
harness
Voltage Between VOL, P (female) (2) and (1) Max. 1 V

Defective operation pres- 2. Put a T-adapter into connector VOL, P.
5 sure sensor of the primary 3. Turn the start switch to the ON position.
flow selector solenoid
Voltage Between VOL, P (2) and (1) 0.8 to 2.0 V
6
40-952 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DHQ2KX]
Circuit diagram related to the oil pressure sensor for the primary flow rate selector valve
HD465-8, HD605-8 40-953

FAILURE CODE [DHQ4KX] 40 TROUBLESHOOTING
FAILURE CODE [DHQ4KX]

Action level Failure code Main Pressure Variable Valve Pressure Sensor Input Signal Out of
Failure Range
L01 DHQ4KX (Transmission controller system)
Details of fail- Voltage of signal circuit of the main pressure variable solenoid operating pressure sensor becomes 0.3 V and
ure below or 4.7 V and above.
Effect of con-
No longer operates the primary pressure flexible solenoid.
troller
Effect on the
Primary pressure variable solenoid does not function and fuel consumption may decrease.
machine
q The monitor function checks the operation pressure of primary pressure variable valve. (Code: 07707
Related infor- (MPa), 07708 (V))

Defective sensor power 2. Disconnect connector M/P, P, and connect T-adapter to the female side.
supply system
Voltage Between M/P, P (female) (3) and (1) Approx. 5 V

2. Disconnect connector ATC1, and connect T-adapter to the female side.
2
ness Between ATC1 (female) (22) and M/P, P (female) (3)
required. Max. 1 Ω
Between ATC1 (female) (21) and M/P, P (female) (1)
Between ATC1 (female) (2) and M/P, P (female) (2) Max. 1 Ω

2. Disconnect connectors ATC1, VOL, P, and M/P, P, and connect a T-adapter to the
Ground fault in wiring har- female side of M/P, P.
3
ness
Between M/P, P (female) (2) and ground Min. 1 MΩ
Resistance
Between M/P, P (female) (3) and ground Min. 1 MΩ

Hot short circuit in wiring 2. Disconnect connector M/P, P, and connect a T-adapter to the female side.
harness
Voltage Between M/P, P (female) (2) and (1) Max. 1 V

Defective operation pres- 2. Put a T-adapter into connector M/P, P.
5 sure sensor of primary 3. Turn the start switch to the ON position.
pressure variable valve
Voltage Between M/P, P (2) and (1) 2.8 to 3.8 V
6
40-954 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DHQ4KX]
Circuit diagram related to main pressure variable valve operation pressure sensor
HD465-8, HD605-8 40-955

FAILURE CODE [DHT5KX] 40 TROUBLESHOOTING
FAILURE CODE [DHT5KX]

Action level Failure code T/C Oil Pressure Sensor Input Signal Out of Range
Failure
L01 DHT5KX (Transmission controller system)
Details of fail- Voltage of signal circuit of the torque converter oil pressure sensor circuit becomes 0.5 V and below or 4.5 V
ure and higher.
Effect of con- Continues controlling when it sets the oil pressure value of the torque converter, at the oil pressure value that
troller is set in the controller.
Effect on the
Large shocks are made when the lockup clutch is engaged.
machine
the hoist lever to "HOLD". Set the lock knob to LOCK and engage the body pivot pin.
Related infor-
mation q The monitor function checks the torque converter oil pressure. (Code: 32605 (V))

Defective sensor power 2. Disconnect connector T/C, P, and connect T-adapter to the female side.
supply system
Voltage Between T/C, P (female) (B) and (A) 20 to 30 V

2. Disconnect connectors ATC1 and T/C, P, and connect T-adapter to each female side.
required. Max. 1 Ω
Open circuit in wiring har- Between ATC1 (female) (16) and T/C, P (female) (B)
2
ness
required. Max. 1 Ω
Between ATC1 (female) (21) and T/C, P (female) (A)
Between ATC1 (female) (1) and T/C, P (female) (C) Max. 1 Ω

2. Disconnect connectors ATC1, and T/C, P, and connect T-adapter to either female side.
Ground fault in wiring har- Between ground and ATC1 (female) (16) or T/C, P (female)
3 Min. 1 MΩ
ness (B)
Resistance
Between ground and ATC1 (female) (1) or T/C, P (female)
Min. 1 MΩ
(C)

Hot short circuit in wiring 2. Disconnect connector T/C, P, and connect a T-adapter to the female side.
harness
Voltage Between T/C, P (female) (C) and ground Max. 1 V

Defective torque converter 2. Put a T-adapter into connector T/C, P.
oil pressure sensor
Voltage Between VOL, P (C) and (A) 0.8 to 2.0 V
40-956 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DHT5KX]

Defective transmission Between ATC1 (16) and (21) 20 to 30 V
6
controller Voltage
Between ATC1 (1) and (21) 0.8 to 2.0 V
Circuit diagram related to the torque converter oil pressure sensor
HD465-8, HD605-8 40-957

FAILURE CODE [DHT5L6] 40 TROUBLESHOOTING
FAILURE CODE [DHT5L6]

Action level Failure code T/C Oil Pressure Sensor Input Signal Mismatch
Failure
L01 DHT5L6 (Transmission controller system)
When the engine is stopped, the transmission controller finds oil pressure corresponding to the input voltage
Details of fail-
from the torque converter oil pressure sensor. (Although the engine is stopped, output voltage of the torque
ure
converter oil pressure sensor does not drop.)
Effect of con- Continues controlling when it sets the oil pressure value of the torque converter, at the oil pressure value that
troller is set in the controller.
Effect on the
Large shocks are made when the lockup clutch is engaged.
machine
hoist lever to "HOLD". Set the lock knob to LOCK and engage the body pivot pin.
Related infor-
mation q The monitor function checks the torque converter oil pressure. (Code: 32605 (V))

2. Disconnect connector T/C, P, and connect a T-adapter to the female side.
1
harness Since the connector is disconnected, ignore the failure code [DHT5KX].
Voltage Between ground and ATC1 (1) or T/C, P (female) (C) Max. 1 V

2. Disconnect connector T/C, P.
Defective torque converter Since the connector is disconnected, ignore the failure code [DHT5KX].
2
oil pressure sensor
q If failure code [DHT5L6] disappears, the torque converter oil pressure sensor is defec-
tive.
q If failure code [DHT5L6] is shown, the wiring harness or transmission controller is de-
fective.

Defective transmission Between ATC1 (16) and (21) 20 to 30 V
3
controller Voltage
40-958 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DHT5L6]
Circuit diagram related to torque converter oil pressure sensor
HD465-8, HD605-8 40-959

FAILURE CODE [DHT8KX] 40 TROUBLESHOOTING
FAILURE CODE [DHT8KX]

Action level Failure code S/T Oil Pressure Sensor Input Signal Out of Range
Failure
L01 DHT8KX (Retarder and hoist controller system)
Details of fail-
Voltage of Signal circuit of the steering angle sensor circuit becomes 0.3 V and below or 4.42 V and higher.
ure
Effect of con-
Cancels automatic secondary steering control.
troller
q Automatic secondary steering function does not work.
Effect on the
q When the start switch is turned to ON, the secondary steering self-check function (that starts automatical-
machine
ly) does not work.
q The monitor function checks the signal from the steering oil pressure sensor. (Code: 95302 (MPa), 95303
Related infor- (V))

2. Disconnect connector H01, and connect a T-adapter to the female side.
1 If the power supply voltage is unusual, examine causes 2 thru 4. If the checks find no fail-
supply system
ure, the sensor power supply system is defective.
Voltage Between H01 (female) (B) and (A) 4.6 to 5.4 V

2. Disconnect connectors BRC1, BRC2, and H01, and connect T-adapter to each female
side.
Between BRC2 (female) (25) and H01 (female) (C) Max. 1 Ω
Open circuit in wiring har- If power supply voltage is normal on cause 1, this check is
2
ness not required. Max. 1 Ω
Resistance Between BRC1 (female) (21) and H01 (female) (A)
If power supply voltage is normal on cause 1, this check is
not required. Max. 1 Ω
Between BRC1 (female) (22) and H01 (female) (B)

2. Disconnect connectors BRC1, BRC2, H01, RE1, RE3, SAC, HTA, HTB, and BK, and
connect T-adapter to the female side of BRC1 and BRC2, or H01.
3 Between ground and BRC2 (female) (25) or H01 (female)
ness Min. 1 MΩ
(C)
Resistance
Between ground and BRC1 (female) (22) or H01 (female)
Min. 1 MΩ
(B)

2. Disconnect connector H01.
Hot short circuit in wiring 3. Insert T-adapter into connector BRC2, or connect T-adapter to the female side of
4 connector H01.
harness
Voltage Between ground and BRC2 (25) or H01 (female) (C) Max. 1 V

2. Disconnect connector H01, and connect a T-adapter to the female side.
Defective steering oil pres- 3. Turn the start switch to the ON position.
5
sure sensor
0.56 to 4.42
Voltage Between H01 (female) (C) and (A)
V
40-960 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DHT8KX]

2. Put a T-adapter into connectors BRC1 and BRC2.
Defective retarder and Between BRC1 (22) and (21) 4.6 to 5.4 V
6
hoist controller Voltage 0.56 to 4.42
Between BRC2 (25) and BRC1 (21)
V
Circuit diagram related to steering oil pressure sensor
HD465-8, HD605-8 40-961

FAILURE CODE [DHT8ZG] 40 TROUBLESHOOTING
FAILURE CODE [DHT8ZG]

Action level Failure code S/T Oil Pressure Low
Failure
L03 DHT8ZG (Retarder and hoist controller system)
Details of fail- Signal of the steering oil pressure sensor during engine operation is 0.56 V and below (oil pressure 0.7 MPa
ure or below).
Effect of con-
During machine travel, automatic secondary steering function operates.
troller
Effect on the
During machine travel, automatic secondary steering function operates.
machine
q Measure the signal from the steering oil pressure sensor with monitor function. (Code: 95302 (MPa),

1 S/T Oil Pressure Low Troubleshoot for hydraulic or mechanical system if the oil pressure is not normal.

2. Disconnect connector H01, and connect T-adapter to the female side.
Defective steering oil pres- 3. Turn the start switch to the ON position.
2
sure sensor
0.56 to 4.42
Voltage Between H01 (female) (C) and (A)
V
3
40-962 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DHU2KX]
FAILURE CODE [DHU2KX]

Action level Failure code Accumulator Oil Pressure Sensor Input Signal Out of Range (Front)
Failure
L01 DHU2KX (Retarder and hoist controller system)
Details of fail- Voltage of signal circuit of the front accumulator oil pressure sensor circuit is 0.3 V and below or 4.7 V or
ure more.
Effect of con-
None in particular
troller
Effect on the
None in particular
machine
q Measure the signal from the front accumulator oil pressure sensor with monitor function. (Code: 35500

2. Put a T-adapter into connector ACCF.
1 If the power supply voltage is unusual, examine causes 2 thru 4. If the checks do not find
supply system
a failure, the sensor power supply system is defective.

2. Disconnect connectors BRC1, BRC2, and ACCF, and connect T-adapter to each
female side.
Between BRC2 (female) (36) and ACCF (female) (2) Max. 1 Ω
2 If power supply voltage is normal on cause 1, this check is
Resistance Between BRC1 (female) (21) and ACCF (female) (1)
Between BRC1 (female) (22) and ACCF (female) (3)

2. Disconnect connectors BRC1, BRC2, ACCF, RE1, RE3, SAC, HTA, HTC, BK, RTSR, and
Ground fault in wiring har- ACCR, and connect T-adapter to each female side of connectors BRC1 and BRC2.
3
ness
Resistance

2. Disconnect connector ACCF.
Hot short circuit in wiring 3. Put a T-adapter into connector BRC2.
4
harness
Voltage Between BRC2 (36) and ground Max. 1 V

Defective front accumula- 2. Put a T-adapter into connector ACCF.
HD465-8, HD605-8 40-963

FAILURE CODE [DHU2KX] 40 TROUBLESHOOTING

6
Between BRC2 (36) and BRC1 (21) 0.3 to 4.7 V
Circuit diagram related to front accumulator oil pressure sensor
40-964 HD465-8, HD605-8


Action level Failure code Accumulator Oil Pressure Sensor Input Signal Out of Range (Rear)
Failure
L01 DHU3KX (Retarder and hoist controller system)
Details of fail- Voltage of signal circuit of the rear accumulator oil pressure sensor circuit becomes 0.3 V and below or 4.7 V
ure and higher.
Effect of con-
None in particular
troller
Effect on the
None in particular
machine
q The monitor function checks the signal from the rear accumulator oil pressure sensor. (Code: 35500

2. Put a T-adapter into connector ACCR.
Defective sensor power If the power supply voltage is unusual, examine causes 2 thru 4. If the checks find no fail-
1
supply system ure, the sensor power supply system is defective.
Battery Volt-
Between ACCR (3) and (1) 4.6 to 5.4 V
age

2. Disconnect the connectors BRC1, BRC2, and ACCF, and connect T-adapter to each
female side.
Between BRC2 (female) (26) and ACCR (female) (2) Max. 1 Ω
2
Resistance Between BRC1 (female) (21) and ACCR (female) (1)
Between BRC1 (female) (22) and ACCR (female) (3)

2. Disconnect connectors BRC1, BRC2, ACCR, RE1, RE3, SAC, HTA, HTC, BK, RTSR,
Ground fault in wiring har- and ACCF, and connect T-adapter to each female side of connectors BRC1 and BRC2.
3
ness
Resistance

2. Disconnect connector ACCR.
4
harness

Defective rear accumula- 2. Put a T-adapter into connector ACCR.
Voltage Between ACCR (2) and (1) 0.3 to 4.7 V
HD465-8, HD605-8 40-965


6
Circuit diagram related to rear accumulator oil pressure sensor
40-966 HD465-8, HD605-8


Action level Failure code ABS control valve pressure sensor (Front Right) circuit Abnormality
Failure
L03 DHU6KX (ABS controller system)
Details of fail- Input voltage of the signal circuit of the ABS control valve pressure sensor (front right) becomes 0.3 V and
Effect of con-
troller
q Check the input signal from the ABS control valve pressure sensor (front right) with monitoring function.
Related infor- (Code: 43314 (MPa), 43315 (V))

2. Disconnect connector BPFR, and connect T-adapter to female side.
Defective sensor power 3. Turn the starting switch to ON position.
supply system
Voltage Between BPFR (female) (B) and (A) 4.6 to 5.4 V

2. Disconnect connectors OPC1 and BPFR, and connect T-adapter to each female side.
Between OPC1 (female) (19) and BPFR (female) (C) Max. 1 Ω
2
Resistance Between OPC1 (female) (21) and BPFR (female) (A)
Between OPC1 (female) (22) and BPFR (female) (B)

2. Disconnect connectors OPC1, ABSP, BPFL, and BPFR, and connect T-adapter to
female side of OPC1 or BPFR.
3 Between ground and OPC1 (female) (19) or BPFR (female)
ness Min. 1 MΩ
(C)
Resistance
Between ground and OPC1 (female) (22) or BPFR (female)
Min. 1 MΩ
(B)

2. Disconnect connector BPFR.
Hot short circuit in wiring 3. Insert T-adapter into connector OPC1, or connect T-adapter to female side of BPFR.
4
harness
Voltage Between ground and OPC1 (19) or BPFR (female) (C) Max. 1 V

Defective ABS control 2. Insert T-adapter into connector BPFR.
5 valve pressure sensor 3. Turn the starting switch to ON position.
(front right)
Voltage Between BPFR (C) and (A) 0.3 to 4.7 V
HD465-8, HD605-8 40-967


6 Defective ABS controller Between OPC1 (22) and (21) 4.6 to 5.4 V
Voltage
Between OPC1 (19) and (21) 0.3 to 4.7 V
Circuit diagram related to ABS control valve pressure sensor (front right)
40-968 HD465-8, HD605-8


Action level Failure code ABS control valve pressure sensor (Front Left) circuit Abnormality
Failure
Details of fail- Input voltage of the signal circuit of the ABS control valve pressure sensor (front left) becomes 0.3 V and
Effect of con-
troller
q Check the input signal from the ABS control valve pressure sensor (front left) with monitoring function.

2. Disconnect connector BPFL, and connect T-adapter to female side.
supply system
Voltage Between BPFL (female) (B) and (A) 4.6 to 5.4 V

2. Disconnect connectors OPC1 and BPFL, and connect T-adapter to each female side.
Between OPC1 (female) (13) and BPFL (female) (C) Max. 1 Ω
2
Resistance Between OPC1 (female) (21) and BPFL (female) (A)
Between OPC1 (female) (22) and BPFL (female) (B)

female side of OPC1 or BPFL.
3 Between ground and OPC1 (female) (13) or BPFL (female)
ness Min. 1 MΩ
(C)
Resistance
Between ground and OPC1 (female) (22) or BPFL (female)
Min. 1 MΩ
(B)

2. Disconnect connector BPFL.
Hot short circuit in wiring 3. Insert T-adapter into connector OPC1, or connect T-adapter to female side of BPFL.
4
harness
Voltage Between ground and OPC1 (13) or BPFL (female) (C) Max. 1 V

Defective ABS control 2. Insert T-adapter into connector BPFR.
(front left)
Voltage Between BPFL (C) and (A) 0.3 to 4.7 V
HD465-8, HD605-8 40-969


Voltage
Circuit diagram related to ABS control valve pressure sensor (front left)
40-970 HD465-8, HD605-8


Action level Failure code ABS control valve pressure sensor (Rear Right) circuit Abnormality
Failure
Details of fail- Input voltage of the signal circuit of the ABS control valve pressure sensor (rear right) becomes 0.5 V and
Effect of con-
troller
q Check the input signal from the ABS control valve pressure sensor (rear right) with monitoring function.

2. Disconnect connector BPRR, and connect T-adapter to female side.
supply system
Voltage Between BPRR (female) (B) and (A) 4.6 to 5.4 V

2. Disconnect connectors OPC1 and BPRR, and connect T-adapter to each female side.
Between OPC1 (female) (7) and BPRR (female) (C) Max. 1 Ω
2
Resistance Between OPC1 (female) (21) and BPRR (female) (A)
Between OPC1 (female) (16) and BPRR (female) (B)

2. Disconnect connectors OPC1, BPRL, and BPRR, and connect T-adapter to female
side of OPC1 or BPRR.
3 Between ground and OPC1 (female) (7) or BPRR (female)
ness Min. 1 MΩ
(C)
Resistance
Between ground and OPC1 (female) (16) or BPRR
Min. 1 MΩ
(female) (B)

2. Disconnect connector BPRR.
Hot short circuit in wiring 3. Insert T-adapter into connector OPC1, or connect T-adapter to female side of BPRR.
4
harness
Voltage Between ground and OPC1 (7) or BPRR (female) (C) Max. 1 V

Defective ABS control 2. Insert T-adapter into connector BPRR.
(rear right)
Voltage Between BPRR (C) and (A) 0.5 to 4.7 V
HD465-8, HD605-8 40-971


Voltage
Circuit diagram related to ABS control valve pressure sensor (rear right)
40-972 HD465-8, HD605-8


Action level Failure code ABS control valve pressure sensor (Rear Left) circuit Abnormality
Failure
Details of fail- Input voltage of the signal circuit of the ABS control valve pressure sensor (rear left) becomes 0.5 V and
Effect of con-
troller
q Check the input signal from the ABS control valve pressure sensor (rear left) with monitoring function.

2. Disconnect connector BPRL, and connect T-adapter to female side.
supply system
Voltage Between BPRL (female) (B) and (A) 4.6 to 5.4 V

2. Disconnect connectors OPC1 and BPRL, and connect T-adapter to each female side.
Between OPC1 (female) (1) and BPRL (female) (C) Max. 1 Ω
2
Resistance Between OPC1 (female) (21) and BPRL (female) (A)
Between OPC1 (female) (16) and BPRL (female) (B)

2. Disconnect connectors OPC1, BPRL, and BPRR, and connect T-adapter to female
side of OPC1 or BPRL.
3 Between ground and OPC1 (female) (1) or BPRL (female)
ness Min. 1 MΩ
(C)
Resistance
Between ground and OPC1 (female) (16) or BPRL (female)
Min. 1 MΩ
(B)

2. Disconnect connector BPRL.
Hot short circuit in wiring 3. Insert T-adapter into connector OPC1, or connect T-adapter to female side of BPRL.
4
harness
Voltage Between ground and OPC1 (1) or BPRL (female) (C) Max. 1 V

Defective ABS control 2. Insert T-adapter into connector BPRL.
(rear left)
Voltage Between BPRL (C) and (A) 0.5 to 4.7 V
HD465-8, HD605-8 40-973


Voltage
Circuit diagram related to ABS control valve pressure sensor (rear left)
40-974 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DHUCKX]
FAILURE CODE [DHUCKX]

Action level Failure code Parking Brake Pressure Sensor Input Signal Out of Range
Failure
L01 DHUCKX (Retarder and hoist controller system)
Details of fail- Voltage of signal circuit of the parking brake oil pressure sensor circuit becomes 0.3 V and below or 4.7 V and
ure higher.
Effect of con-
None in particular
troller
Effect on the
None in particular
machine
q The monitor function checks the signal from the parking brake oil pressure sensor. (Code: 91908 (MPa),

2. Put a T-adapter into connector PPSR.
1 If the power supply voltage is unusual, examine causes 2 thru 4. If the check finds no fail-
supply system
ure, the sensor power supply is defective.
Voltage Between PPSR (3) and (1) 4.6 to 5.4 V

2. Disconnect connectors BRC1, BRC2, and PPSR, and connect T-adapter to each
female side.
Between BRC2 (female) (5) and PPSR (female) (2) Max. 1 Ω
Resistance Between BRC1 (female) (21) and PPSR (female) (1)
Between BRC1 (female) (22) and PPSR (female) (3)

2. Disconnect connectors BRC1, BRC2, PPSR, HTB, HTC, and BK, and connect
Ground fault in wiring har- T-adapter to each female side of BRC1 and BRC2.
3
ness
Resistance

2. Disconnect connector PPSR.
Hot short circuit in wiring 3. Insert T-adapter into connector BRC2.
4
harness

Defective parking brake oil 2. Put a T-adapter into connector PPSR.
pressure sensor
Voltage Between PPSR (2) and (1) 0.3 to 4.7 V
HD465-8, HD605-8 40-975

FAILURE CODE [DHUCKX] 40 TROUBLESHOOTING

6
40-976 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DHUCKX]
Circuit diagram related to parking brake oil pressure sensor
HD465-8, HD605-8 40-977

FAILURE CODE [DHUDKX] 40 TROUBLESHOOTING
FAILURE CODE [DHUDKX]

Action level Failure code Secondary S/T Pressure Sensor 1 Input Signal Out of Range
Failure
L01 DHUDKX (Retarder and hoist controller system)
Details of fail- Voltage of Signal circuit of the secondary steering oil pressure sensor becomes 0.3 V and below or 4.42 V
ure and higher.
Effect of con-
Continues controls of automatic secondary steering.
troller
Effect on the When the start switch is turned to ON, the secondary steering self-check function (that starts automatically)
machine does not work.
q The monitor function checks the signal from the secondary steering oil pressure sensor.
Related infor- (Code: 07703(MPa), 07705(V))

2. Put a T-adapter into connector H02.
1 If the power supply voltage is unusual, examine causes 2 thru 4. If the check finds no fail-
supply system
ure, the sensor power supply is defective.
Voltage Between H02 (B) and (A) 4.6 to 5.4 V

2. Disconnect connectors BRC1, BRC2, and H02, and connect T-adapter to each female
side.
Between BRC2 (female) (15) and H02 (female) (C) Max. 1 Ω
Resistance Between BRC1 (female) (21) and H02 (female) (A)
Between BRC1 (female) (22) and H02 (female) (B)

2. Disconnect connectors BRC1, BRC2, H01, RE1, RE3, SAC, HTA, HTB, and BK, and
Ground fault in wiring har- connect T-adapter to the female side of BRC1 and BRC2.
3
ness
Resistance

2. Disconnect connector H02.
4
harness

Defective secondary steer- 2. Put a T-adapter into connector H02.
ing oil pressure sensor
Voltage Between H02 (C) and (A) 0.3 to 4.7 V
40-978 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DHUDKX]

Defective retarder and Between BRC1 (22) and BRC1 (21) 4.6 to 5.4 V
6
Circuit diagram related to secondary steering oil pressure sensor
HD465-8, HD605-8 40-979

FAILURE CODE [DHUHKX] 40 TROUBLESHOOTING
FAILURE CODE [DHUHKX]

Action level Failure code Secondary Brake Pressure Sensor Signal Out of Range
Failure
L01 DHUHKX (Retarder and hoist controller system)
Details of fail-
Voltage of signal circuit of the steering angle sensor becomes 0.3 V and below or 4.7 V or more.
ure
Effect of con-
None in particular
troller
Effect on the
Stop lamp does not illuminate or stay illuminated when the secondary brake pedal depressed.
machine
q Measure the input signal from the pressure sensor with monitor function. (Code: 91917 (MPa), 91918 (V))
Related infor-
mation

Defective sensor power 2. Disconnect connector S02, and connect T-adapter to the female side.
supply system
Voltage Between S02 (female) (3) and (1) Approx. 5 V

2. Disconnect connectors BRC1 and S02, and connect T-adapter to each female side.
Between BRC1 (female) (21) and S02 (1) Max. 1 Ω
2
Resistance Between BRC1 (female) (7) and S02 (2)
required. Max. 1 Ω
Between BRC1 (female) (22) and S02 (3)

2. Disconnect connectors BRC2, S02, RE1, RE3, SAC, HTA, HTC, and HTB, and
Ground fault in wiring har- connect T-adapter to each female side of S02.
3
ness
Between S02 (female) (2) and ground Min. 1 MΩ
Resistance
Between S02 (female) (3) and ground Min. 1 MΩ

Hot short circuit in wiring 2. Disconnect connector S02, and connect T-adapter to the female side.
harness
Voltage Between S02 (female) (2) and (1) Max. 1 V

2. Put a T-adapter into connector S02.
Secondary brake oil pres-
5 0.30 to 0.58
sure sensor Secondary brake: OFF
V
Voltage Between S02 (2) and (1)
1.82 to 1.95
Secondary brake: ON
V
40-980 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DHUHKX]

6
hoist controller Voltage Between BRC1 (22) and (21) 4.6 to 5.4 V
Circuit diagram related to secondary brake oil pressure sensor
HD465-8, HD605-8 40-981

FAILURE CODE [DHULKX] 40 TROUBLESHOOTING
FAILURE CODE [DHULKX]

Action level Failure code KTCS Pressure Sensor Signal Out of Range (Rear Right)
Failure
L01 DHULKX (Retarder and hoist controller system)
Details of fail-
Voltage of signal circuit of the KTCS oil pressure sensor (rear right) is 0.3 V and below or 4.7 V or more.
ure
Effect of con-
None in particular
troller
Effect on the
None in particular
machine
q Signal from the pressure sensor can be seen on monitor function. (Code: 49006 (MPa), 49007 (V))
Related infor-
mation

Defective sensor power 2. Disconnect connector TCS5, and connect T-adapter to the female side.
supply system
Voltage Between TCS5 (female) (3) and (1) 4.6 to 5.4 V

2. Disconnect connectors BRC1, BRC2, and TCS5, and connect T-adapter to each
female side of TCS5.
Between BRC1 (female) (13) and TCS5 (female) (2) Max. 1 Ω
Resistance Between BRC1 (female) (4) and TCS5 (female) (1)
required. Max. 1 Ω
Between BRC2 (female) (1) and TCS5 (female) (3)

2. Disconnect connectors BRC1, BRC2, TCS5, HSL, EG, RLB, and TCS6, and connect
Ground fault in wiring har- T-adapter to each female side of TCS5.
3
ness
Between TCS5 (female) (2) and ground Min. 1 MΩ
Resistance

Hot short circuit in wiring 2. Disconnect connector TCS5, and connect T-adapter to the female side.
harness
Voltage Between TCS5 (female) (2) and (1) Max. 1 V

2. Put a T-adapter into connector TCS5.
REMARK
For details of KTCS valve set mode, see "PROCEDURE TO ADJUST WITH ADJUST-
Defective KTCS oil pres-
5 MENT MENU (KTCS VALVE SETTING)".
sure Sensor (rear right)
0.30 to 0.59
KTCS: OFF
V
Voltage Between TCS5 (1) and (2) KTCS: ON
1.09 to 1.26
(When set to ON with KTCS
V
Valve Setting mode)
40-982 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DHULKX]

REMARK
MENT MENU (KTCS VALVE SETTING)".
6
hoist controller
0.30 to 0.59
KTCS: OFF
V
Voltage Between BRC2 (16) and
BRC1 (4) KTCS: ON
1.09 to 1.26
V
Valve Setting mode)
Circuit diagram related to KTCS pressure sensor (rear right)
HD465-8, HD605-8 40-983

FAILURE CODE [DHUMKX] 40 TROUBLESHOOTING
FAILURE CODE [DHUMKX]

Action level Failure code KTCS Pressure Sensor Signal Out of Range (Rear Left)
Failure
L01 DHUMKX (Retarder and hoist controller system)
Details of fail-
Voltage of signal circuit of the KTCS oil pressure sensor (rear left) becomes 0.3 V and below or 4.7 V or more.
ure
Effect of con-
None in particular
troller
Effect on the
None in particular
machine
q Signal from the pressure sensor is seen on monitor function. (Code: 49004 (MPa), 49005 (V))
Related infor-
mation

Defective sensor power 2. Disconnect connector TCS6, and connect T-adapter to the female side.
supply system
Voltage Between TCS6 (female) (3) and (1) 4.6 to 5.4 V

female side.
Resistance Between BRC1 (female) (4) and TCS6 (female) (1)
required. Max. 1 Ω
Between BRC2 (female) (1) and TCS6 (female) (3)

2. Disconnect connectors BRC1, BRC2, TCS6, HSL, EG, RLB, and TCS5, and connect
Ground fault in wiring har- T-adapter to each female side of TCS6.
3
ness
Resistance

harness
Voltage Between TCS6 (female) (2) and (1) Max. 1 V

2. Put a T-adapter into connector TCS6.
REMARK
sure Sensor (rear left)
0.30 to 0.59
KTCS: OFF
V
Voltage Between TCS6 (1) and (2) KTCS: ON
1.09 to 1.26
V
Valve Setting mode)
40-984 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DHUMKX]

REMARK
MENT MENU (KTCS VALVE SETTING)".
6
hoist controller
0.30 to 0.59
KTCS: OFF
V
Voltage Between BRC2 (16) and
BRC1 (4) KTCS: ON
1.09 to 1.26
V
Valve Fixing mode)
Circuit diagram related to KTCS pressure sensor (rear left)
HD465-8, HD605-8 40-985

FAILURE CODE [DHUPKX] 40 TROUBLESHOOTING
FAILURE CODE [DHUPKX]

Action level Failure code Retarder Pressure Sensor Signal Out of Range (Rear)
Failure
L01 DHUPKX (Retarder and hoist controller system)
Details of fail-
Voltage of signal circuit of the retarder oil pressure sensor (rear) becomes 0.3 V and below or 4.7 V or more.
ure
Effect of con-
None in particular
troller
Effect on the
None in particular
machine
q Signal from the pressure sensor is seen on monitor function. (Code: 91910 (MPa), 91912 (V))
Related infor-
mation

Defective sensor power 2. Disconnect connector RTSR, and connect T-adapter to the female side.
supply system
Voltage Between RTSR (3) and (1) 4.6 to 5.4 V

2. Disconnect connectors BRC1 and RTSR, and connect T-adapter to each female side.
Between BRC1 (female) (19) and RTSR (female) (2) Max. 1 Ω
2
Resistance Between BRC1 (female) (21) and RTSR (female) (1)
required. Max. 1 Ω
Between BRC1 (female) (22) and RTSR (female) (3)

2. Disconnect connectors BRC1, RTSR, RE1, RE3, SAC, HTC, HTA, BK, ACCF, and
Ground fault in wiring har- ACCR, and connect T-adapter to each female side of RTSR.
3
ness
Between RTSR (female) (2) and ground Min. 1 MΩ
Resistance
Between RTSR (female) (3) and ground Min. 1 MΩ

Hot short circuit in wiring 2. Disconnect connector RTSR, and connect T-adapter to the female side.
harness
Voltage Between RTSR (female) (2) and (1) Max. 1 V

5 0.30 to 0.59
sure Sensor (rear left) Retarder control lever: OFF
V
Voltage Between RTSR (1) and (2)
1.09 to 1.26
Retarder control lever: ON
V
40-986 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DHUPKX]

Between BRC1 (22) and (21) 4.6 to 5.4 V
Defective retarder and 0.30 to 0.59
6 Retarder control lever: OFF
hoist controller Voltage V
(21) 1.09 to 1.26
V
Circuit diagram related to the retarder pressure sensor (rear)
HD465-8, HD605-8 40-987

FAILURE CODE [DHUTKX] 40 TROUBLESHOOTING
FAILURE CODE [DHUTKX]

Action level Failure code ABS Cut valve pressure sensor Abnormality
Failure
L03 DHUTKX (ABS controller system)
Details of fail- Input voltage of the signal circuit of the ABS cut valve pressure sensor becomes 0.3 V and below or 4.7 V and
ure above.
Effect of con-
None in particular
troller
Effect on the
None in particular
machine
q Check the input signal from the ABS cut valve pressure sensor with monitoring function. (Code: 43402

2. Disconnect connector ABSP, and connect T-adapter to female side.
supply system
Voltage Between ABSP (female) (3) and (1) 4.6 to 5.4 V

2. Disconnect connectors OPC1 and ABSP, and connect T-adapter to each female side.
Between OPC1 (female) (2) and ABSP (female) (2) Max. 1 Ω
Open circuit in wiring har- If power supply voltage is normal on the cause 1, the fol-
2
ness lowing check is not required. Max. 1 Ω
Resistance Between OPC1 (female) (21) and ABSP (female) (1)
If power supply voltage is normal on the cause 1, the fol-
lowing check is not required. Max. 1 Ω
Between OPC1 (female) (22) and ABSP (female) (3)

female side of OPC1 or ABSP.
3 Between ground and OPC1 (female) (2) or ABSP (female)
ness Min. 1 MΩ
(2)
Resistance
Between ground and OPC1 (female) (22) or ABSP (female)
Min. 1 MΩ
(3)

2. Disconnect connector ABSP.
Hot short circuit in wiring 3. Insert T-adapter into connector OPC1, or connect T-adapter to female side of ABSP.
4
harness
Voltage Between ground and OPC1 (2) or ABSP (female) (2) Max. 1 V

Defective ABS cut valve 2. Insert T-adapter into connector ABSP.
pressure sensor
Voltage Between ABSP (2) and (1) 0.3 to 4.7 V
40-988 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DHUTKX]

Voltage
Circuit diagram related to ABS cut valve pressure sensor
HD465-8, HD605-8 40-989

FAILURE CODE [DHY9KX] 40 TROUBLESHOOTING
FAILURE CODE [DHY9KX]

Action level Failure code Steering/Hoist Pump Oil Pressure Sensor Out of Range
Failure
L03 DHY9KX (Transmission controller system)
Details of fail- Voltage of the signal circuit of the steering/hoist pump oil pressure sensor becomes 0.3 V and below or 4.42
ure V and above.
Effect of con-
troller
Effect on the
Machine lockout function cannot be activated.
machine
q If the failure codes [DHY9KX], [DHQ4KX], [DHQ2KX] are all displayed, ground circuit in the wiring har-
Related infor- ness branched off from ATC1 (22) or hot short circuit in a wiring harness may have occurred.

2. Disconnect connector WPP, and connect T-adapter to female side.
1 If power supply voltage is abnormal, check on cause 2 to 4. If no failure is found by the
supply system
checks, the sensor power supply system of the transmission controller is defective.
Voltage Between WPP (female) (B) and (A) 4.6 to 5.4 V

2. Disconnect connectors ATC1 and WPP, and connect T-adapter to each female side.
Between ATC1 (female) (7) and WPP (female) (C) Max. 1 Ω
2
Resistance Between ATC1 (female) (21) and WPP (female) (A)
Between ATC1 (female) (22) and WPP (female) (B)

2. Disconnect connectors ATC1, WPP, M/P, and VOL, and connect T-adapter to female
side of ATC1 or WPP.
3 Between ground and ATC1 (female) (7) or WPP (female)
ness Min. 1 MΩ
(C)
Resistance
Between ground and ATC1 (female) (22) or WPP (female)
Min. 1 MΩ
(B)

2. Disconnect connector WPP.
Hot short circuit in wiring 3. Insert T-adapter into connector ATC1, or connect T-adapter to female side of
4 connector WPP.
harness
Voltage Between ground and ATC1 (7) or WPP (female) (C) Max. 1 V

Defective steering/hoist 2. Insert T-adapter into connector WPP.
pump oil pressure sensor
Voltage Between WPP (C) and (A) 0.3 to 4.42 V
40-990 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DHY9KX]

Defective transmission Between ATC1 (22) and (21) 4.6 to 5.4 V
6
controller Voltage
If no failure is found by the above checks, the transmission controller is defective. (Since
this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to steering/hoist pump oil pressure sensor
HD465-8, HD605-8 40-991

FAILURE CODE [DJF1KA] 40 TROUBLESHOOTING
FAILURE CODE [DJF1KA]

Action level Failure code Fuel Level Sensor Open Circuit
Failure
L01 DJF1KA (Machine monitor system)
Details of fail-
Voltage of signal circuit of the fuel level sensor becomes 2 V or more.
ure
Effect of con-
Turns off the hand of the fuel level gauge.
troller
Effect on the
Pointer of the fuel level gauge disappears from screen, fuel level is not identified.
machine
q Input signal from fuel level sensor can be checked by monitor function. (Code: 04200 (V), 04201 (Ω))
Related infor-
mation

2. Disconnect connector FUEL2, and connect T-adapter to the male side.
1 Defective fuel level sensor
Between FUEL2 (male) (1) Fuel level: When full Max. 20 Ω
Resistance
and (2) Fuel level: When empty 70 to 100 Ω

Open circuit or hot short 2. Disconnect connector FUEL2, and connect T-adapter to the female side.
circuit in wiring harness
Voltage Between FUEL2 (female) (1) and (2) Approx. 3.3 V
If no failure is found by the check on cause 2, this check is not required.
Open or short circuit in wir- 2. Disconnect connector MCM1, and connect T-adapter to the female side.
3
ing harness
Between MCM1 (female) (8) Fuel level: When full Max. 20 Ω
Resistance
and (9) Fuel level: When empty 70 to 100 Ω
2. Disconnect connectors MCM1 and FUEL2, and connect T-adapter to each female
4 side.
ness
Between MCM1 (female) (8) and FUEL2 (female) (1) Max. 1 Ω
Resistance
Between MCM1 (female) (9) and FUEL2 (female) (2) Max. 1 Ω
5
40-992 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DJF1KA]
Circuit diagram related to fuel level sensor
HD465-8, HD605-8 40-993

FAILURE CODE [DK30KX] 40 TROUBLESHOOTING
FAILURE CODE [DK30KX]

Action level Failure code Steering Angle Potentiometer Input Signal Out of Range
Failure
L01 DK30KX (Retarder and hoist controller system)
Details of fail-
Voltage of signal circuit of the steering angle sensor becomes 0.3 V and below or 4.7 V or more.
ure
Effect of con-
Cancel KTCS control.
troller
Effect on the
KTCS control does not work.
machine
q Examine the signal from the steering angle sensor with monitor function. (Code: 35402 (deg), 35400 (V))
Related infor-
mation
Procedure: Start the engine and turn the steering wheel completely in each direction.

2. Disconnect connector TCS1, and connect T-adapter to the male side.
REMARK
{(A) to B)} + {(B) to (C)} = (A) to (C) = 5 kΩ±20%
Defective steering angle
1 Between TCS1 (male) (A) and (C) 5 kΩ±20 %
sensor
0 to 5 kΩ
Between TCS1 (male) (A) and (B)
Resistance ±20 %
0 to 5 kΩ
Between TCS1 (male) (B) and (C)
±20 %

2. Disconnect connectors BRC1 and BRC2, and connect T-adapter to each female side.
2
ing harness Between BRC2 (female) (1) and BRC1 (female) (4) 4 to 6 kΩ
Resistance
Between BRC1 (female) (5) and (4) 1.5 to 3.5 kΩ
3
ness Between BRC2 (female) (1) and TCS1 (female) (C) Max. 1 Ω
Resistance Between BRC1 (female) (5) and TCS1 (female) (B) Max. 1 Ω
Between BRC1 (female) (4) and TCS1 (female) (A) Max. 1 Ω

2. Disconnect connectors BRC1, BRC2, TCS1, HSL, RLB, and TCSA1, and connect
T-adapter to the female side of BRC1 and BRC2, or TCS1.
4 Between ground and BRC2 (female) (1) or TCS1 (female)
ness Min. 1 MΩ
(C)
Resistance
Between ground and BRC1 (female) (5) or TCS1 (female)
Min. 1 MΩ
(B)
40-994 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DK30KX]

2. Disconnect connectors BRC1, BRC2, and TCS1, and connect T-adapter to the female
side of BRC1 and BRC2, or TCS1.
5
ness Between BRC1 (female) (5) and (4), or between TCS1
Min. 1 MΩ
(female) (A) and (B)
Resistance
Min. 1 MΩ
between TCS1 (female) (B) and (C)

2. Disconnect connector TCS1, and connect T-adapter to the female side.
6
harness
Between TCS1 (female) (B) and (A) Max. 1 V
Voltage
Between TCS1 (female) (C) and (A) 4.6 to 5.4 V

2. Put a T-adapter into connector BRC1 or TCS1.
3. Start the engine and turn the steering wheel completely in each direction.
7 1.15 to 3.85
hoist controller Voltage Between BRC1 (5) and (4), or between TCS1 (B) and (A)
V
Circuit diagram related to steering angle sensor
HD465-8, HD605-8 40-995

FAILURE CODE [DK51L5] 40 TROUBLESHOOTING
FAILURE CODE [DK51L5]

Action level Failure code Retarder Lever Potentiometer Input Signal and RVS Signal Mismatch
Failure
L03 DK51L5 (Retarder and hoist controller system)
Details of fail- Signal circuit voltage of the retarder control lever potentiometer is 0.3 V and below or 4.7 V or more, or poten-
ure tiometer signal and the switch signal coincide.
Takes the action that follows corresponding to the failure.
Effect of con- q Controls by using the potentiometer signal.
troller q Limits operation of the retarder EPC valve to 70%.
q Stops operation of the retarder EPC valve.
Takes the action that follows corresponding to the failure.
Effect on the q None in particular
machine q Precise control of the retarder is not available
q Retarder does not work. (The foot brake works.)
q Examine the voltage of the retarder control lever potentiometer with monitor function. (Code: 33900 (V))
Related infor-
mation

2. Disconnect connectors BRC1, BRC3, RE1, and RTL, and connect T-adapter to each
female side.
Between BRC1 (female) (22) and RE1 (female) (1) Max. 1 Ω
Between RE1 (female) (2) and RTL (female) (1) Max. 1 Ω
Open circuit in wiring har- Between BRC1 (female) (21) and RTL (female) (3) Max. 1 Ω
1
ness
Between BRC1 (female) (8) and RTL (female) (2) Max. 1 Ω
Resistance
Between RTL (female) (6) and BRC3 (female) (21), (31),
Max. 1 Ω
(32), and (33)

2. Disconnect connectors BRC1, RE1, RTL, RE3, SAC, and J07, and connect T-adapter
to any two of the female side, BRC1, RE1, or RTL.
Ground fault in wiring har- Between ground and BRC1 (female) (22) or RE1 (female)
2 Min. 1 MΩ
ness (1)
Resistance Between ground and RE1 (female) (2) or RTL (female) (1) Min. 1 MΩ
Between ground and BRC1 (female) (8) or RTL (female)
Min. 1 MΩ
(2)

2. Disconnect connector RTL.
3. Insert T-adapter into connector BRC1, or connect T-adapter to the female side of
Hot short circuit in wiring connector RTL.
3
harness 4. Turn the start switch to the on position.
Between ground and BRC1 (22) or RTL (female) (1) 4.6 to 5.4 V
Voltage
Between ground and BRC1 (8) or RTL (female) (2) Max. 1 V

4 Defective transistor (RE1) 2. Disconnect connector RE1, and connect T-adapter to the male side.
40-996 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DK51L5]

2. Put a T-adapter into connector RTL.
4. Examine the potentiometer.
Between RTL (1) and (3) 4.1 to 4.8 V
Voltage
Between RTL (2) and (3) 0.3 to 4.7 V
Defective retarder control 1. Turn the start switch to the OFF position.
5
lever
2. Disconnect connector RTL, and connect T-adapter to the male side.
3. Check switch.
Between RTL (male) (4) and Lever in the OFF position Max. 1 Ω
(6) Lever in the ON position Min. 1 MΩ
Resistance
Between RTL (male) (5) and Lever in the OFF position Min. 1 MΩ
(6) Lever in the ON position Max. 1 Ω

Between BRC1 (22) and BRC3 (21), (31), (32), and (33) 4.6 to 5.4 V
Voltage
Between BRC1 (8) and BRC3 (21), (31), (32), and (33) 0.3 to 4.7 V

Defective retarder and 2. Disconnect connector BRC2, and connect T-adapter to the female side.
6 3. Check switch.
hoist controller
Between BRC2 (female) Lever in the OFF position Max. 1 Ω
(13) and ground Lever in the ON position Min. 1 MΩ
Resistance
Between BRC2 (female) (3) Lever in the OFF position Min. 1 MΩ
and ground Lever in the ON position Max. 1 Ω
HD465-8, HD605-8 40-997

Circuit diagram related to retarder control lever potentiometer
40-998 HD465-8, HD605-8


Action level Failure code Hoist Lever Potentiometer Input Signal Out of Range
Failure
Details of fail- Voltage of the signal circuit of the hoist lever potentiometer (main) or the potentiometer (sub) becomes 0.3 V
ure or below, or 4.7 V or more.
q Controls using the normal potentiometer out of the 2 sets.
Effect of con-
q If both the main circuit and sub circuit are defective, the controller Recognizes the hoist lever as the HOLD
troller
position.
Effect on the
If the main and sub circuits are defective, the dump body will not move.
machine
q Signal voltage of hoist lever potentiometer signal circuit (main) or (sub) can be seen on monitor function.
Related infor- (Code: 34304, 34305 (V))

2. Disconnect connectors BRC1, BRC2, and HSL, and connect T-adapter to each female
side.
Open circuit in wiring har- Between BRC1 (female) (4) and HSL (female) (1) Max. 1 Ω
1
ness
Between BRC1 (female) (18) and HSL (female) (2) Max. 1 Ω
Resistance

2. Disconnect connectors BRC1, BRC2, HSL and J07, and connect T-adapter to the
female side of BRC1 and BRC2, or HSL.
Between ground and BRC2 (female) (1) or HSL (female)
Ground fault in wiring har- Min. 1 MΩ
2 (4)
ness
(2)
Min. 1 MΩ
(3)

2. Disconnect connector HSL, and connect T-adapter to the female side.
3 harness (contact with the Between HSL (female) (4) and ground 4.6 to 5.4 V
power supply circuit).
Voltage Between HSL (female) (2) and ground Max. 1 V
Between HSL (female) (3) and ground Max. 1 V

2. Put a T-adapter into connector HSL.
Between HSL (4) and (1) 4.6 to 5.4 V
4 Defective hoist lever
Hoist lever is in HOLD posi-
Voltage tion.
Hoist lever is in FLOAT posi- 1.47 to 2.01
Between HSL (3) and (1)
tion. V
HD465-8, HD605-8 40-999


5
hoist controller Voltage Between BRC1 (18) and (4) 0.3 to 4.7 V
Circuit diagram related to hoist lever potentiometer
40-1000 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DK53L8]
FAILURE CODE [DK53L8]

Action level Failure code Hoist Lever Potentiometer 1 or 2 Signal Abnormality
Failure
L03 DK53L8 (Retarder and hoist controller system)
Details of fail- The total voltage of the signal circuit of the hoist lever potentiometer (main) or the potentiometer (sub) is 4.4 V
ure or below, or 5.6 V or more.
Effect of con-
Recognizes the hoist lever as the HOLD position.
troller
Effect on the
Dump body does not move.
machine
q Signal voltage of hoist lever potentiometer signal circuit (main) or (sub) can be seen on monitor function.
Related infor- (Code: 34304, 34305 (V))

Short circuit in wiring har- 2. Disconnect connectors BRC1, BRC2, and HSL, and connect T-adapter to the female
1 side of HSL.
ness
Resistance Between HSL (female) (2) and (3) Min. 1 MΩ

2. Disconnect connector HSL, and connect T-adapter to the male side.
Resistance Between HSL (male) (2) and (3) Min. 1 MΩ

2. Put a T-adapter into connector HSL.
2 Defective hoist lever 3. Turn the start switch to the ON position.
Voltage Between HSL (3) and (1) 0.3 to 4.7 V
Total value between HSL (2) and (1), and between (3) and
4.5 to 5.5 V
(1)
3
HD465-8, HD605-8 40-1001

Circuit diagram related to hoist lever potentiometer
40-1002 HD465-8, HD605-8


Action level Failure code Body Positioner Sensor Input Signal Out of Range
Failure
Details of fail-
Signal voltage of the incline angle sensor circuit is 0.3 V and below or 4.7 V and above.
ure
Effect of con- q Controls the dump body corresponding to the signals from the hoist lever.
troller q Controls dump body corresponding to the dump body not against the seat.
q Dump body seat shock increases.
Effect on the q Hoist lever positioner does not function.
machine q Maximum selectable gear speed is limited.
q The machine cannot travel in reverse when the dump lever is in a position other than FLOAT.
q Signal from body position sensor is seen on the monitor function. (Code: 34603 (V))
Related infor-
mation

2. Disconnect connector B07, and connect T-adapter to the male side.
Defective body position
1 Between B07 (male) (C) and (A) 5 kΩ±20 %
sensor
Resistance 0 to 5 kΩ
Between B07 (male) (B) and (A)
±20 %

2. Disconnect connectors BRC1 and BRC2, and B07, and connect T-adapter to each
female side.
2 Between BRC1 (female) (6) and B07 (female) (B) Max. 1 Ω
ness
Resistance Between BRC2 (female) (1) and B07 (female) (C) Max. 1 Ω
Between BRC1 (female) (4) and B07 (female) (A) Max. 1 Ω

2. Disconnect connectors BRC1, BRC2, B07, HSL, EG, and TCSA1, and connect
T-adapter to the female side of BRC1 and BRC2, or B07.
3 Between ground and BRC1 (female) (6) or B07 (female)
ness Min. 1 MΩ
(B)
Resistance
Between ground and BRC2 (female) (1) or B07 (female)
Min. 1 MΩ
(C)

2. Disconnect connector B07.
3. Insert T-adapter into connector BRC1 and BRC2, or connect T-adapter to the female
side of connector B07.
4 harness (contact with the
power supply circuit). 4. Turn the start switch to the ON position.
Between ground and BRC1 (6) or B07 (female) (B) Max. 1 V
Voltage
Between ground and BRC2 (1) or B07 (female) (C) Max. 1 V
HD465-8, HD605-8 40-1003


0.30 to 0.62
Defective retarder and Between BRC1 (6) and (4) Dump body is seated.
5 V
With dump body cylinder rod
Max
Circuit diagram related to dump body position sensor
40-1004 HD465-8, HD605-8


Action level Failure code Acceleration Sensor Input Signal Out of Range
Failure
Details of fail-
Signal from the acceleration sensor is 0.5 V and below, or 4.5 V and above.
ure
Effect of con-
Continues KTCS control.
troller
Effect on the
KTCS control does not work.
machine
Related infor-
Inspect the input signal from the accelerator sensor with monitor function. (Code: 60201 (V))
mation

Defective sensor power 2. Disconnect connector SAC, and connect T-adapter to the female side.
supply system
Voltage Between SAC (female) (1) and (3) 4.6 to 5.4 V

2. Disconnect connectors BRC1 and SAC, and connect T-adapter to each female side.
Between BRC1 (female) (1) and SAC (female) (2) Max. 1 Ω
2 required. Max. 1 Ω
ness
Resistance Between BRC1 (female) (22) and SAC (female) (1)
required. Max. 1 Ω
Between BRC1 (female) (21) and SAC (female) (3)

2. Disconnect connectors BRC1, SAC, RE1, RE3, and J07, and connect T-adapter to the
female side of BRC1 or SAC.
Ground fault in wiring har- Between ground and BRC1 (female) (1) or SAC (female)
3 Min. 1 MΩ
ness (2)

required.
Min. 1 MΩ
Between ground and BRC1 (female) (22) or SAC (female)
(1)

2. Disconnect connector SAC.
4 connector SAC.
harness
Voltage Between ground and BRC1 (1) or SAC (female) (2) Max. 1 V

2. Insert T-adapter into connector SAC.
Defective acceleration sen- 3. Turn the start switch to the ON position.
5
sor
Between SAC (2) and (3)
in a horizontal, stable condition
HD465-8, HD605-8 40-1005


3. Turn the start switch to the OK position.
6
hoist controller Voltage Between BRC1 (1) and (21)
2.2 to 2.8 V
Circuit diagram related to acceleration sensor
40-1006 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DKD0L6]
FAILURE CODE [DKD0L6]

Action level Failure code Steering Angle Speed Sensor System Abnormality
Failure
L01 DKD0L6 (Retarder and hoist controller system)
Details of fail-
Signal from the steering angle sensor is abnormal.
ure
Effect of con-
Cancel automatic suspension control.
troller
Effect on the
The automatic suspension is in medium mode.
machine
Related infor-
mation

2. Disconnect connector SR3, and connect T-adapter to the female side.
1
supply system
Battery Volt-
Between SR3 (female) (1) and (3) 20 to 30 V
age

2. Disconnect connectors BRC1, BRC2, and SR3, and connect T-adapter to each female
side.
2 Between BRC2 (female) (29) and SR3 (female) (3)
ness
Resistance Between BRC2 (female) (37) and SR3 (female) (2) Max. 1 Ω
required. Max. 1 Ω
Between BRC1 (female) (16) and SR3 (female) (1)

2. Disconnect connectors BRC1, BRC2, and SR3, and connect T-adapter to either
female side.
Ground fault in wiring har- Between ground and BRC2 (female) (37) or SR3 (female)
3 Min. 1 MΩ
ness (2)

required.
Min. 1 MΩ
Between ground and BRC1 (female) (16) or SR3 (female)
(1)

Hot short circuit in wiring 2. Disconnect connector SR3, and connect T-adapter to the female side.
4
Voltage Between SR3 (female) (2) and (3) Max. 1 V

2. Connect T-adapter to connector SR3.
Defective steering speed 3. Start the engine.
5
sensor
4. Turn the steering wheel slowly.
Voltage Between SR3 (2) and (3) See Fig. 1
HD465-8, HD605-8 40-1007

FAILURE CODE [DKD0L6] 40 TROUBLESHOOTING

2. Connect T-adapter into connectors BRC1 and BRC2.
Voltage Between BRC1 (16) and BRC2 (29) 20 to 30 V

6 2. Connect T-adapter into connector BRC2.
hoist controller
4. Turn the steering wheel slowly.
Voltage Between BRC2 (37) and (29) See Fig. 1
Circuit diagram related to steering angle sensor
40-1008 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DKH0KX]
FAILURE CODE [DKH0KX]

Action level Failure code Inclination Angle Sensor Input Signal Out of Range (Lateral)
Failure
L01 DKH0KX (Retarder and hoist controller system)
Details of fail-
Voltage of signal circuit of the incline angle sensor is 0.3 V and below or 4.7 V and above.
ure
Effect of con-
None in particular
troller
Effect on the
Failure code of Gradient Caution [989D00] is not sensed.
machine
q Input signal from the incline angle sensor is seen on monitor function. (Code: 32904 (°C), 32905 (V))
Related infor-
mation

Defective sensor power 2. Disconnect connector T10A, and connect T-adapter to female side.
supply system
Voltage Between T10A (female) (C) and (A) 20 to 30 V

2. Disconnect connectors BRC1, BRC2, and T10A, and connect T-adapter to each
female side.
Between BRC2 (female) (6) and T10A (female) (B) Max. 1 Ω
Resistance Between BRC1 (female) (16) and T10A (female) (C)
required. Max. 1 Ω
Between BRC1 (female) (4) and T10A (female) (A)

2. Disconnect connectors BRC1, T10A, SR3, and VH2, and connect T-adapter to the
female side of BRC1 and BRC2, or T10A.
Ground fault in wiring har- Between ground and BRC2 (female) (6) or T10A (female)
3 Min. 1 MΩ
ness (B)
Resistance If power supply voltage is normal, the following check is not

required.
Min. 1 MΩ
Between ground and BRC1 (female) (16) or T10A (female)
(C)

2. Disconnect connector T10A.
4 connector T10A.
harness
Voltage Between ground and BRC2 (6) or T10A (female) (B) Max. 1 V

2. Insert T-adapter into connector T10A.
Defective incline angle 3. Turn the start switch to the ON position.
5
sensor
Between T10A (B) and (A)
HD465-8, HD605-8 40-1009

FAILURE CODE [DKH0KX] 40 TROUBLESHOOTING

Defective retarder and Between BRC1 (16) and (4) 20 to 30 V

6
hoist controller Voltage Between BRC2 (6) and BRC1 (4)
2.2 to 2.8 V
Circuit diagram related to the incline angle sensor
40-1010 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DKH1KX]
FAILURE CODE [DKH1KX]

Action level Failure code Inclination Angle Sensor Input Signal Out of Range (Longitudinal)
Failure
L01 DKH1KX (KOMTRAX Plus controller system)
Details of fail-
Voltage of signal circuit of incline angle sensor is 0.3 V and below or 4.7 V or more.
ure
Effect of con-
None in particular
troller
Phenomenon
Payload is not shown correctly.
on machine
q If failure code [DBV6KB] is shown, troubleshoot for it first.
Related infor- q Input voltage from the incline angle sensor can be checked by monitor function. (Code: 32902)
mation q After the repair is completed, make sure the failure code is cleared by the procedure that follows.

Defective sensor power 2. Connect T-adapter to the female side of connector PM3.
supply system
Voltage Between PM3 (female) (C) and (A) Approx. 24 V

2. Disconnect connectors KPS1, KPS2, and PM3, and connect T-adapter to each female
side.
Between KPS1 (female) (14) and PM3 (female) (B) Max. 1 Ω
2
Resistance Between KPS2 (female) (49) and PM3 (female) (C)
required. Max. 1 Ω
Between KPS1 (female) (1) and PM3 (female) (A)

Ground fault in wiring har- 2. Disconnect connectors KPS1 and PM3, and connect T-adapter to either female side.
3
ness Between ground and KPS1 (female) (14) or PM3 (female)
(B)

2. Disconnect connector PM3.
Hot short circuit in wiring 3. Insert T-adapter into connector KPS1, or connect T-adapter to the female side of
4 connector PM3.
harness
Voltage Between ground and KPS1 (14) or PM3 (female) (B) Max. 1 V

2. Insert T-adapter into connector PM3.
Defective inclination angle 3. Turn the starting switch to the ON position.
5
sensor
Between PM3 (B) and (A)
Approximately 2.6 V when machine is level
HD465-8, HD605-8 40-1011

FAILURE CODE [DKH1KX] 40 TROUBLESHOOTING

2. Connect T-adapter to connectors KPS1 and KPS2.
6
controller Voltage Between KPS1 (14) and KPS1 (1)
0.5 to 4.5 V
Approximately 2.6 V when machine is level
If there is no failure by the previous checks, KOMTRAX Plus controller is defective. (Since
this is an internal defect, you cannot troubleshoot.)
Circuit diagram related to inclination angle sensor
40-1012 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DLF1KA]
FAILURE CODE [DLF1KA]

Action level Failure code T/M Input Speed Sensor Open Circuit
Failure
L03 DLF1KA (Transmission controller system)
Details of fail-
No signal is input from the transmission input shaft speed sensor due to open circuit in its signal circuit.
ure
q Keeps gear speed and disengages lockup clutch.
Effect of con- q Transmission will stay in neutral when the gear shift lever is set to the "N" position.
troller q Although the cause of failure is eliminated, the machine is not normal until the start switch is turned to the
OFF position.
q Lockup clutch is disengaged and gear shifting becomes impossible.
q If the gear shift lever is set to "N" during travel, and the lever is moved from the "N" position, the gear will
Effect on the not shift. The machine must stop before the gear will shift.
machine q After the machine stops, it can move forward when the gear speed is set to F2 by setting the gear shift
lever to a position between D and L. The machine can move backward when the gear speed is set to R
by setting the gear shift lever to R position.
hoist lever to the "HOLD" position and set the lock knob to the LOCK position. Make sure to en-
Related infor- gage the body pivot pin.
mation q Transmission input shaft speed is seen on monitor function. (Code: 31200 (rpm))
q After the repair is completed, remove the failure code by this procedure.

2. Disconnect connector N1, and connect T-adapter to the male side.
1 500 to 1000
input shaft speed sensor Between N1 (male) (1) and (2)
Resistance Ω
Between ground and N1 (male) (1) or (2) Min. 1 MΩ

2. Disconnect connectors ATC2 and N1, and connect T-adapter to each female side.
2
ness Between ATC2 (female) (40) and N1 (female) (1) Max. 1 Ω
Resistance
Between ATC2 (female) (39) and N1 (female) (2) Max. 1 Ω
Defective transmission If there is no failure found by the previous checks, the transmission controller is defective.
3
controller (Since this is an internal failure, you cannot troubleshoot.)
Circuit diagram related to transmission input shaft speed sensor
HD465-8, HD605-8 40-1013

FAILURE CODE [DLF1LC] 40 TROUBLESHOOTING
FAILURE CODE [DLF1LC]

Action level Failure code T/M Input Speed Sensor Hot Short Circuit or Ground Fault
Failure
L03 DLF1LC (Transmission controller system)
Details of fail- Transmission input shaft speed calculated from signals of engine s, transmission intermediate and output
ure shaft speed sensors differs from the transmission input shaft speed sensor.
OFF position.
mation q Transmission input shaft speed is seen on monitor function. (Code: 31200 (rpm))
Procedure: Start the engine, operate the machine in F1, and turn on the lockup pilot lamp.

Screw in the sensor until it touches the speed sensor gear lightly, then turn it back out by
Defective adjustment of the 1/2 to 1 turn.
1 transmission input shaft REMARK
speed sensor For details, see TEST AND ADJUST, "CHECK AFTER ADJUSTMENT OF TRANSMIS-
SION SPEED SENSORS".

2 500 to 1000
input shaft speed sensor Between N1 (male) (1) and (2)
Resistance Ω

Ground fault in wiring har- 2. Disconnect connectors ATC1, ATC2, and N2, and connect T-adapter to any female
3 side.
ness
Resistance Between ground and ATC2 (female) (40) or N1 (female) (1) Min. 1 MΩ

Hot short circuit in wiring 2. Connect T-adapter to connector N1.
harness
Voltage Between N1 (female) (1) and ground 1.0 to 4.5 V

2. Disconnect connectors ATC2 and N1, and connect T-adapter to the female side of
Short circuit in wiring har- ATC2.
5
ness
(40)
6
40-1014 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DLF1LC]
Circuit diagram related to transmission input shaft speed sensor
HD465-8, HD605-8 40-1015

FAILURE CODE [DLF2KA] 40 TROUBLESHOOTING

Action level Failure code T/M Intermediate Speed Sensor Open Circuit
Failure
L03 DLF2KA (Transmission controller system)
Details of fail- No signal is input from the transmission middle shaft speed sensor because of an open circuit in its signal cir-
ure cuit.
q Maintains the same gear speed during travel.
OFF position.
q The gear will not shift
mation q Examine the transmission intermediate shaft speed with monitor function. (Code: 31300 (rpm))

1 intermediate shaft speed 500 to 1000
sensor Between N2 (male) (1) and (2)
Resistance Ω

2. Disconnect connectors ATC1, ATC2, and N2, and connect T-adapter to each female
2
ness
Resistance
3
Circuit diagram related to transmission intermediate shaft speed sensor
40-1016 HD465-8, HD605-8


Action level Failure code T/M Intermediate Speed Sensor Hot Short Circuit or Ground Fault
Failure
L03 DLF2LC (Transmission controller system)
Details of fail- Transmission middle shaft speed calculated from signals of the engine, transmission input shaft and output
ure shaft speed sensors differs from the transmission middle shaft speed sensor.
q Maintains the same gear speed during travel.
OFF position.
mation q Examine the transmission middle shaft speed with monitor function. (Code: 31300 (V))

Screw in the sensor until it touches the speed sensor gear lightly, then turn it back out by
Defective adjustment of 1/2 to 1 turn.
1 transmission middle shaft REMARK
speed sensor For details, see TEST AND ADJUST, "CHECK AFTER ADJUSTMENT OF TRANSMIS-
SION SPEED SENSORS".

2 500 to 1000
middle shaft speed sensor Between N2 (male) (1) and (2)
Resistance Ω

Ground fault in wiring har- 2. Disconnect connectors ATC2 and N2, and connect T-adapter to either female side.
3
ness

Hot short circuit in wiring 2. Disconnect connector N2, and connect T-adapter to the female side.
harness

2. Disconnect connectors ATC2 and N2, and connect T-adapter to the female side of
Short circuit in wiring har- ATC2.
5
ness
(20)
6
HD465-8, HD605-8 40-1017

Circuit diagram related to transmission intermediate shaft speed sensor
40-1018 HD465-8, HD605-8


Action level Failure code Wheel Speed Sensor (Front Right) Disconnection
Failure
L03 DLF6KA (ABS controller system)
Details of fail-
No signal is input from the wheel speed sensor (front right).
ure
Effect of con-
troller
Related infor- After the repair is completed, remove the failure code by this procedure.

2. Disconnect connectors OPC2 and WSFR, and connect T-adapter to each female side.
1
ness Between OPC2 (female) (40) and WSFR (female) (1) Max. 1 Ω
Resistance
Between OPC2 (female) (29) and WSFR (female) (2) Max. 1 Ω

Hot short circuit in wiring 2. Disconnect connector WSFR, and connect T-adapter to female side.
harness
Voltage Between WSFR (female) (1) and (2) 1.0 to 4.5 V
q Check the speed measured by the wheel speed sensor (front right) when the unloaded
machine is traveling on a dry road with monitoring function. (Code: 39702 (rpm))
q Start the engine and drive the machine.
Defective wheel speed Speed When stopped 0 rpm
3
sensor (front right) detected by
wheel speed
sensor (front When traveling at 10 km/h 10 to 40 rpm
right)
Circuit diagram related to wheel speed sensor (front right)
HD465-8, HD605-8 40-1019

FAILURE CODE [DLF6L3] 40 TROUBLESHOOTING
FAILURE CODE [DLF6L3]

Action level Failure code Wheel Speed Sensor (Front Right) Malfunction
Failure
L03 DLF6L3 (ABS controller system)
Details of fail-
Signal from wheel speed sensor (front right) is abnormal.
ure
Effect of con-
troller
Related infor- q After the repair is completed, remove the failure code by this procedure.

2. Disconnect connectors OPC2 and WSFR, and connect T-adapter to each female side.
1
ness Between OPC2 (female) (40) and WSFR (female) (1) Max. 1 Ω
Resistance
Between OPC2 (female) (29) and WSFR (female) (2) Max. 1 Ω

2. Disconnect connectors OPC2 and WSFR, and connect T-adapter to either female
2
ness
Between ground and OPC2 (female) (40) or WSFR
(female) (1)

2. Disconnect connectors OPC2 and WSFR, and connect T-adapter to either female
3
ness
Between OPC2 (female) (40) and (29), or between WSFR

Hot short circuit in wiring 2. Disconnect connector WSFR, and connect T-adapter to female side.
harness
Voltage Between WSFR (female) (1) and (2) 1.0 to 4.5 V
q Check the speed measured by the wheel speed sensor (front right) when the unloaded
5
sensor (front right) detected by
wheel speed
right)
40-1020 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DLF6L3]
Circuit diagram related to wheel speed sensor (front right)
HD465-8, HD605-8 40-1021


Action level Failure code Wheel Speed Sensor (Front Left) Disconnection
Failure
L03 DLF7KA (ABS controller system)
Details of fail-
No signal is input from the wheel speed sensor (front left).
ure
Effect of con-
troller

2. Disconnect connectors OPC2 and WSFL, and connect T-adapter to each female side.
1
ness Between OPC2 (female) (30) and WSFL (female) (1) Max. 1 Ω
Resistance
Between OPC2 (female) (29) and WSFL (female) (2) Max. 1 Ω

Hot short circuit in wiring 2. Disconnect connector WSFL, and connect T-adapter to female side.
harness
Voltage Between WSFL (female) (1) and (2) 1.0 to 4.5 V
q Check the speed measured by the wheel speed sensor (front left) when the unloaded
3
sensor (front left) detected by
wheel speed
left)
Circuit diagram related to wheel speed sensor (front left)
40-1022 HD465-8, HD605-8


Action level Failure code Wheel Speed Sensor (Front Left) Malfunction
Failure
Details of fail-
Signal from wheel speed sensor (front left) is abnormal.
ure
Effect of con-
troller

2. Disconnect connectors OPC2 and WSFL, and connect T-adapter to each female side.
1
ness Between OPC2 (female) (30) and WSFL (female) (1) Max. 1 Ω
Resistance
Between OPC2 (female) (29) and WSFL (female) (2) Max. 1 Ω

2. Disconnect connectors OPC2 and WSFL, and connect T-adapter to either female
2
ness
Between ground and OPC2 (female) (30) or WSFL
(female) (1)

2. Disconnect connectors OPC2 and WSFL, and connect T-adapter to either female
3
ness
Between OPC2 (female) (30) and (29), or between WSFL

Hot short circuit in wiring 2. Disconnect connector WSFL, and connect T-adapter to female side.
harness
Voltage Between WSFL (female) (1) and (2) 1.0 to 4.5 V
q Check the speed measured by the wheel speed sensor (front left) when the unloaded
5
sensor (front left) detected by
wheel speed
left)
HD465-8, HD605-8 40-1023

Circuit diagram related to wheel speed sensor (front left)
40-1024 HD465-8, HD605-8


Action level Failure code Wheel Speed Sensor Open Circuit (Rear Right)
Failure
L01 DLF8KA (Retarder and hoist controller system)
Details of fail-
No signal is input from the wheel speed sensor (rear right).
ure
Effect of con-
q Although the cause of failure is eliminated, the machine is not normal until the start switch is turned to the
troller
OFF position.
Effect on the
KTCS does not work.
machine

2. Disconnect connectors BRC1, BRC2, and WSRR, and connect T-adapter to each
1
ness
Between BRC2 (female) (20) and WSRR (female) (1) Max. 1 Ω
Resistance

Hot short circuit in wiring 2. Disconnect connector WSRR, and connect T-adapter to the female side.
harness
Voltage Between WSRR (female) (2) and (1) 1.0 to 4.5 V
q Examine the speed measured by the wheel speed sensor (rear right) when the un-
loaded machine travels on a dry road with the monitor function. (Code: 39704)
q Procedure: Start the engine and operate the machine.
3
sensor (rear right) detected by
wheel speed
sensor (rear When traveling at 10 km/h 10 to 40 rpm
right)
Defective retarder and If there is no failure found by the previous checks, the retarder and hoist controller is
4
hoist controller defective. (Since this is an internal defect, you cannot troubleshoot.)
Circuit diagram related to wheel speed sensor (rear right)
HD465-8, HD605-8 40-1025


Action level Failure code Wheel Speed Sensor (Rear Right) Malfunction
Failure
Details of fail-
Signal input to the retarder and hoist controller from the wheel speed sensor (rear right) is abnormal.
ure
Effect of con-
troller
q If failure code [DLF8LC] is also displayed, perform troubleshooting for it first.
Related infor-
mation
Procedure: Start the engine and operate the machine.

Defective wheel speed
sensor (rear right), wiring
1 Perform troubleshooting for failure code [DLF8LC].
harness, and retarder and
hoist controller
40-1026 HD465-8, HD605-8


Action level Failure code Wheel Speed Sensor System Abnormality (Rear Right)
Failure
L01 DLF8LC (Retarder and hoist controller system)
Details of fail-
Signal from wheel speed sensor (rear right) is incorrect.
ure
Effect of con-
troller
OFF position.
Effect on the
KTCS does not work.
machine

2. Disconnect connectors BRC1, BRC2, and WSRR, and connect T-adapter to each
1
ness
Resistance

2. Disconnect connectors BRC2 and WSRR, and connect T-adapter to either female
2
ness
Between ground and BRC2 (female) (20) or WSRR
(female) (1)

2. Disconnect connectors BRC1, BRC2, and WSRR, and connect T-adapter to any
3
ness
between WSRR (female) (2) and (1)

Hot short circuit in wiring 2. Disconnect connector WSRR, and connect T-adapter to female side.
harness
Voltage Between WSRR (female) (2) and (1) 1.0 to 4.5 V
q Examine the speed measured by the wheel speed sensor (rear right) when the un-
loaded machine travels on a dry road with the monitor function. (Code: 39704)
q Start the engine and operate the machine.
5
sensor (rear right) detected by
wheel speed
sensor (rear When you travel at 10 km/h 10 to 40 rpm
right)
6
HD465-8, HD605-8 40-1027

40-1028 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DLF8MA]
FAILURE CODE [DLF8MA]

Action level Failure code Wheel Speed Sensor (Rear Right) Disconnection
Failure
L03 DLF8MA (ABS controller system)
Details of fail-
No signal is input to the retarder and hoist controller from the wheel speed sensor (rear right).
ure
Effect of con-
troller
q The same failure is inspected by the retarder and hoist controller in the failure code [DLF8KA].
Related infor-
mation

sensor (rear right), wiring
1 Perform troubleshooting for failure code [DLF8KA].
harness, or retarder and
hoist controller
HD465-8, HD605-8 40-1029


Action level Failure code Wheel Speed Sensor Open Circuit (Rear Left)
Failure
L01 DLF9KA (Retarder and hoist controller system)
Details of fail-
No signal is input from the wheel speed sensor (rear left).
ure
Effect of con-
troller
OFF position.
Effect on the
KTCS does not work.
machine

2. Disconnect connectors BRC2 and WSRL, and connect T-adapter to each female side.
1
ness Between BRC2 (female) (10) and WSRL (female) (1) Max. 1 Ω
Resistance
Between BRC2 (female) (39) and WSRL (female) (2) Max. 1 Ω

Hot short circuit in wiring 2. Disconnect connector WSRL, and connect T-adapter to the female side.
harness
Voltage Between WSRL (female) (1) and (2) 1.0 to 4.5 V
q Examine the speed measured by the wheel speed sensor (rear left) when the unload-
ed machine travels on a dry road with the monitor function. (Code: 39705)
3
sensor (rear left) sensed by
wheel speed
left)
4
Circuit diagram related to wheel speed sensor (rear left)
40-1030 HD465-8, HD605-8


Action level Failure code Wheel Speed Sensor (Rear Left) Malfunction
Failure
Details of fail-
Signal input to the retarder and hoist controller from the wheel speed sensor (rear left) is abnormal.
ure
Effect of con-
troller
q If failure code [DLF9LC] is also displayed, perform troubleshooting for it first.
Related infor-
mation

sensor (rear left), wiring
1 Perform troubleshooting for failure code [DLF9LC].
hoist controller
HD465-8, HD605-8 40-1031


Action level Failure code Wheel Speed Sensor System Abnormality (Rear Left)
Failure
L01 DLF9LC (Retarder and hoist controller system)
Details of fail-
Signal from the wheel speed sensor (rear left) is incorrect.
ure
Effect of con-
troller
OFF position.
Effect on the
KTCS does not work.
machine

2. Disconnect connectors BRC2 and WSRL, and connect T-adapter to each female side.
1
ness Between BRC2 (female) (10) and WSRL (female) (1) Max. 1 Ω
Resistance
Between BRC2 (female) (39) and WSRL (female) (2) Max. 1 Ω

2. Disconnect connectors BRC2 and WSRL, and connect T-adapter to either female
2
ness
Between ground and BRC2 (female) (10) or WSRL
(female) (1)

2. Disconnect connectors BRC2 and WSRL, and connect T-adapter to either female
3
ness
Between BRC2 (female) (39) and (10), or between WSRL

Hot short circuit in wiring 2. Disconnect connector WSRL, and connect T-adapter to the female side.
harness
Voltage Between WSRL (female) (1) and (2) 1.0 to 4.5 V
q Examine the speed measured by the wheel speed sensor (rear left) when the unload-
ed machine travels on a dry road with the monitor function. (Code: 39705)
5
sensor (rear left) sensed by
wheel speed
left)
6
40-1032 HD465-8, HD605-8

HD465-8, HD605-8 40-1033

FAILURE CODE [DLF9MA] 40 TROUBLESHOOTING
FAILURE CODE [DLF9MA]

Action level Failure code Wheel Speed Sensor (Rear Left) Disconnection
Failure
L03 DLF9MA (ABS controller system)
Details of fail-
No signal is input to the retarder and hoist controller from the wheel speed sensor (rear left).
ure
Effect of con-
troller
q The same failure is inspected by the retarder and hoist controller in the failure code [DLF9KA].
Related infor-
mation

sensor (rear left), wiring
1 Perform troubleshooting for failure code [DLF9KA].
hoist controller
40-1034 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DLM3KA]
FAILURE CODE [DLM3KA]

Action level Failure code Radiator Fan Speed Sensor Open Circuit or Hot Short Circuit
Failure
L01 DLM3KA (Transmission controller system)
Details of fail- Radiator fan speed becomes "0" when open circuit is sensed in the signal circuit of the radiator fan speed
ure sensor.
q Cancels radiator fan feed back control.
Effect of con-
troller
OFF position.
Effect on the
Target speed is not achieved, fuel consumption may increase or engine may become too hot.
machine

2. Disconnect connector RSS, and connect T-adapter to the male side.
Defective radiator fan
1 1500 to 3500
speed sensor Between RSS (male) (1) and (2)
Resistance Ω
Between RSS (male) (1) and ground Min. 1 MΩ

2
ness Between ATC2 (female) (10) and RSS (female) (1) Max. 1 Ω
Resistance
Between ATC1 (female) (4) and RSS (female) (2) Max. 1 Ω

Hot short circuit in wiring 2. Disconnect connector RSS, and connect T-adapter to the female side.
harness
Voltage Between RSS (female) (1) and ground 1.0 to 4.5 V
4
Circuit diagram related to radiator fan speed sensor
HD465-8, HD605-8 40-1035

FAILURE CODE [DLM3LC] 40 TROUBLESHOOTING
FAILURE CODE [DLM3LC]

Action level Failure code Radiator Fan Speed Sensor Signal Abnormality
Failure
L01 DLM3LC (Transmission controller system)
Details of fail-
Radiator fan speed becomes "0" when the engine operates and the radiator fan turns in the normal direction.
ure
Effect of con-
troller
OFF position.
Effect on the
machine

1 1500 to 3500
Resistance Ω

2. Disconnect connector ATC1 and ATC2, and connect T-adapter to each female side.
2
ness Between ATC2 (female) (10) and RSS (female) (1) Max. 1 Ω
Resistance
Between ATC1 (female) (4) and RSS (female) (2) Max. 1 Ω

Ground fault in wiring har- 2. Disconnect connectors ATC2 and RSS, and connect T-adapter to either female side.
3
ness Between ground and ATC2 (female) (10) or RSS (female)
(1)

2. Disconnect connectors ATC2 and RSS.
Short circuit in wiring har- 3. Connect T-adapter to the female side of connector ATC2.
4
ness
(10)

2. Disconnect connector RSS.
Hot short circuit in wiring 3. Insert T-adapter into connector ATC2, or connect T-adapter to connector RSS.
5
Between ground and ATC2 (female) (10) or RSS (female)
(1)
6
40-1036 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DLM3LC]
HD465-8, HD605-8 40-1037

FAILURE CODE [DLM3MB] 40 TROUBLESHOOTING
FAILURE CODE [DLM3MB]

Action level Failure code Radiator Fan Speed Sensor Function Deterioration
Failure
L01 DLM3MB (Transmission controller system)
Details of fail- Difference between real speed and target speed of the radiator fan exceeds 400 rpm while the engine oper-
ure ates and radiator fan turns in the normal direction.
Effect of con-
troller
OFF position.
Effect on the
machine
q Target speed of radiator fan is seen on monitor function. (Code: 10007 (rpm))
Related infor- q Radiator fan speed is seen on monitor function. (Code: 10009 (rpm))
mation q After the repair is completed, remove the failure code by this procedure.

q Increase hydraulic oil temperature to 50 °C and above, and turn the start switch to the
OFF position once. Then start the engine again and check for this failure code again.
Differences in perfor- q If it is shown again, perform the checks that follow.
1 mance because of hydrau-
lic oil temperature
REMARK
Temperature sensed by the steering oil temperature sensor is seen on monitor function.
(Code: 32701)

2 1500 to 3500
Resistance Ω
3
40-1038 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DLT3KA]
FAILURE CODE [DLT3KA]

Action level Failure code T/M Output Speed Sensor Open Circuit
Failure
L03 DLT3KA (Transmission controller system)
Details of fail- No signal is input from the the transmission output speed sensor because of an open circuit in its signal cir-
ure cuit.
OFF position.
Effect on the
machine
not shift. The machine must stop before the gear will shift.
mation q Transmission output shaft speed is seen on monitor function. (Code: 31400 (rpm))

Defective transmission out-
1 500 to 1000
put shaft speed sensor Between N3 (male) (1) and (2)
Resistance Ω
Between N3 (male) (1), (2) and ground Min. 1 MΩ

2. Disconnect connectors ATC2 and N3, and connect T-adapter to each female side.
2
ness Between ATC2 (female) (30) and N3 (female) (1) Max. 1 Ω
Resistance
3
Circuit diagram related to transmission output shaft speed sensor
HD465-8, HD605-8 40-1039

FAILURE CODE [DLT3LC] 40 TROUBLESHOOTING
FAILURE CODE [DLT3LC]

Action level Failure code T/M Output Speed Sensor Open Circuit or Short Circuit
Failure
L01 DLT3LC (Retarder and hoist controller system)
Details of fail- The values calculated from signals of the transmission output shaft speed sensor, wheel speed sensor (rear
ure right), and wheel speed sensor (rear left) are incorrect.
Effect of con-
Cancel controls of KTCS, ARSC, and automatic suspension.
troller
Effect on the q KTCS and ARSC do not work.
machine q Automatic suspension is set in moderate mode.
mation q If failure code [DLT3KA] is also shown, troubleshoot for it first.

Defective transmission out-
1 500 to 1000
put shaft speed sensor Between N3 (male) (1) and (2)
Resistance Ω
Between N3 (male) (1) and ground Min. 1 MΩ

Ground fault in wiring har- 2. Disconnect connectors ATC2 and N3, and connect T-adapter to either female side.
2
ness

Hot short circuit in wiring 2. Disconnect connector N3, and connect T-adapter to the female side.
harness

2. Disconnect connector N3.
4
ness
(30)
5
40-1040 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DLT3LC]
Circuit diagram related to transmission output shaft speed sensor
HD465-8, HD605-8 40-1041

FAILURE CODE [DPQ1KR] 40 TROUBLESHOOTING
FAILURE CODE [DPQ1KR]

Action level Failure code LIN Defective Communication (Switch Panel)
Failure
L01 DPQ1KR (Machine monitor system)
Details of fail- Update of data received from the switch panel (control switch on the machine monitor) via the LIN communi-
ure cation is interrupted.
Effect of con-
None in particular
troller
q You can neither enter the user menu and service menu screens nor perform setting using these menus.
Effect on the q You cannot control the Air conditioner.
machine q SMR is not shown on the screen while the start switch is in OFF position.
q If the engine start lock is activated, you cannot start the engine since you cannot enter the password.
q When failure code [DPQ2KR] or [DPQ3KR] is shown on screen at the same time, ground or hot short cir-
Related infor- cuit may occur in LIN communication line.

Ground error or hot short
1 circuit in 12 V power supply If failure code [DAFDKB] is shown, troubleshoot for [DAFDKB] first.
line of switch panel

Open circuit in 12 V power 2. Disconnect connector OPM, and connect T-adapter to the female side.
supply line of switch panel
Voltage Between OPM (female) (1) and (2) 9 to 14 V

Defective 5 V power supply 2. Disconnect connector OPM, and connect T-adapter to the female side.
line of switch panel
Voltage Between OPM (female) (4) and (2) 4 to 6 V
When failure code [DPQ2KR] and [DPQ3KR] are not shown at the same time, this check
is not required.
Hot short circuit in wiring 1. Turn the start switch to the OFF position.
4 harness (LIN communica- 2. Disconnect connector OPM, and connect T-adapter to the female side.
tion line) 3. Turn the start switch to the ON position.
Voltage Between OPM (female) (3) and (2) Approx. 9 V
q When failure code [DPQ2KR] and [DPQ3KR] are not shown at the same time, this
check is not required.
q If there is no failure found by check on cause 4, this check is not required.
Ground fault in wiring har- 1. Turn the start switch to the OFF position.
5 2. Disconnect connectors MCM2, DPC2, OPM, and RMN1, and connect T-adapter to
ness
any female side.
Between ground and MCM2 (female) (108), DPC2 (female)
(3), OPM (female) (3), or RMN1 (female) (9)
When failure code [DPQ2KR] or [DPQ3KR] is shown on screen at the same time, perform
this check.
Defective switch panel 1. Turn the start switch to the OFF position.
6 (control switch on machine 2. Disconnect connector OPM.
monitor) 3. Turn the start switch to the ON position.
When failure code [DPQ2KR] and [DPQ3KR] are not shown, the switch panel is defective.
40-1042 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DPQ1KR]

this check.
Defective LED unit (display 1. Turn the start switch to the OFF position.
7 2. Disconnect connector DPC2.
unit on machine monitor)
When failure code [DPQ1KR] and [DPQ3KR] are not shown, the LED unit is defective.
this check.
8 Defective rearview monitor 2. Disconnect connector RMN1.
When failure code [DPQ1KR] and [DPQ2KR] are not shown, the rearview monitor is
defective.
Defective monitor control- If there is no failure found by the previous checks, the monitor controller is defective.
9
ler (Since this is an internal defect, you cannot troubleshoot).
HD465-8, HD605-8 40-1043

Circuit diagram related to LIN communication (switch panel)
40-1044 HD465-8, HD605-8


Action level Failure code LIN Defective Communication (LED Unit)
Failure
Details of fail- Update of data received from the LED unit (display unit on the machine monitor) via the LIN communication is
ure interrupted.
Effect of con-
None in particular
troller
The displays that follow are different from the real displays.
q Winker lamp (hazard lamp)
q High beam
Effect on the
q Parking brake pilot lamp
machine
q Brake oil pressure caution lamp
q Clearance lamp pilot lamp
q Centralized warning lamp
q When failure code [DPQ1KR] or [DPQ3KR] show on screen at the same time, ground or hot short circuit
Related infor- may occur in the LIN communication line.

Ground fault or hot short
1 circuit in 12 V power supply If failure code [DAFDKB] is shown, troubleshoot for [DAFDKB] first.
line of LED unit

Open circuit in 12 V power 2. Disconnect connector DPC2, and connect T-adapter to the female side.
supply line of LED unit
Voltage Between DPC2 (female) (1) and (2) 9 to 14 V

Defective 5 V power supply 2. Disconnect connector DPC2, and connect T-adapter to the female side.
line of LED unit
Voltage Between DPC2 (female) (4) and (2) 4 to 6 V
is not required.
4 harness (LIN communica- 2. Disconnect connector DPC2, and connect T-adapter to the female side.
Voltage Between DPC2 (female) (3) and (2) Approx. 9 V
ness
any female side.
HD465-8, HD605-8 40-1045


this check.
6 (control switch on machine 2. Disconnect connector OPM.
When failure code [DPQ2KR] and [DPQ3KR] are not displayed, the switch panel is defec-
tive.
this check.
this check.
defective.
9
40-1046 HD465-8, HD605-8

Circuit diagram related to LIN communication (LED unit)
HD465-8, HD605-8 40-1047


Action level Failure code LIN Defective Communication (Rearview Monitor)
Failure
Details of fail-
Update of data received from rearview monitor via the LIN communication is interrupted.
ure
Effect of con-
None in particular
troller
Effect on the Rearview camera display related settings are disabled (guide line display, reverse-interlock selection mode,
machine guide line position adjustment, rearview monitor initialization).
q When failure code [DPQ1KR] or [DPQ2KR] is on the screen at the same time, ground or hot short may
Related infor- occur in the LIN communication line.

If the fuse No.7 in the fuse box BT2 is blown out, the circuit probably has a ground error,
1 Defective fuse
or other type of failure.
2 down secondary switch If failure code [DDAAL6] is shown, troubleshoot for [DDAAL6] first.
system

2. Disconnect connector RMN1, and connect T-adapter to the female side.
3 Defective power supply
Between RMN1 (female) (1) and (2) 20 to 30 V
Voltage
Between RMN1 (female) (12) and (2) 20 to 30 V
is not required.
4 harness (LIN communica- 2. Disconnect connector RMN1, and connect T-adapter to the female side.
Voltage Between RMN1 (female) (9) and (2) Approx. 9 V
ness
any female side.
When failure code [DPQ1KR] or [DPQ2KR] is shown on the screen at the same time, per-
form the check that follows.
6 (control switch on machine 2. Disconnect connector RMN1.
When failure code [DPQ2KR] and [DPQ3KR] are not shown, the switch panel is defective.
40-1048 HD465-8, HD605-8


defective.
9
HD465-8, HD605-8 40-1049

Circuit diagram related to LIN communication (rearview monitor)
40-1050 HD465-8, HD605-8

Circuit diagram related to LIN communication (rearview monitor) (For machines equipped with emergency engine
stop switch)
HD465-8, HD605-8 40-1051

FAILURE CODE [DSJ0KR] 40 TROUBLESHOOTING
FAILURE CODE [DSJ0KR]

Action level Failure code CAN 2 Defective Communication (Meter Unit)
Failure
L03 DSJ0KR (Detected by monitor controller) (Machine monitor system)
Details of fail- Monitor controller does not recognize the meter unit of the machine monitor over CAN 2 communication line
ure (KOMNET/c).
Effect of con-
None in particular
troller
Effect on the q Engine tachometer indicates "0".
machine q Speedometer shows "00".
q ACC signal of start switch is the command to start CAN communication for each controller.
q Monitor controller senses 6 different failure codes, [DBVQKR], [DAQQKR], [DAZQKR], [DB1QKR],
[DB2QKR] and [DSJ0KR] for defective CAN 2 CAN communication. When all 6 failure codes are shown,
ground error, short circuit, or hot short circuit in wiring harness (CAN communication line) is suspect.
Since the air conditioner also operates through the CAN communication, check the air conditioner oper-
ation on the air conditioner screen. (ON/OFF and air flow adjustment)
mation Machine with ABS system also displays failure code [DBCQKR].
q If the air conditioner is operable, wiring harness (CAN communication line) does not have ground error,
q Each controller and machine monitor (meter unit) are connected directly to the battery. They are supplied
with power although the start switch is turned to the OFF position.

To troubleshoot refer "METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL"
1 meter unit of machine mon-
in E mode.
itor
Defective CAN 2 communi-
cation system
Defective meter unit of If there is no failure found by the previous checks, the machine monitor is defective.
3
machine monitor (Since this is an internal defect, you cannot troubleshoot).
4
40-1052 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DV00KB]
FAILURE CODE [DV00KB]

Action level Failure code Buzzer Output Circuit Ground Fault
Failure
L01 DV00KB (Machine monitor system)
Details of fail-
Unusual current flows when power is output to alarm buzzer circuit.
ure
q Stops power to the alarm buzzer circuit.
Effect of con-
troller
OFF position.
Effect on the
Alarm buzzer does not sound.
machine
q The operation condition of alarm buzzer (ON/OFF) is seen on monitor function. (Code: 04700)
Related infor-
mation

2. Disconnect connector BZ2, and connect T-adapter to the female side.
NOTICE
If these voltages are normal and alarm buzzer does not operate, alarm buzzer is de-
1 Defective alarm buzzer
fective.
Turn the start switch to the
Max. 1 V
Between BZ2 (female) (1) OFF position.
Voltage
and (2) Turn the start switch to the
20 to 30 V
ON position.

Ground fault in wiring har- 2. Disconnect connectors MCM1 and BZ2, and connect T-adapter to either female side.
2
ness Between ground and MCM1 (female) (20) or BZ2 (female)
(1)

2. Insert T-adapter into connector BZ2.
3 Turn the start switch to the
ler Max. 1 V
OFF position.
Voltage Between BZ2 (1) and (2)
Turn the start switch to the
20 to 30 V
ON position.
HD465-8, HD605-8 40-1053

FAILURE CODE [DV00KB] 40 TROUBLESHOOTING
Circuit diagram related to alarm buzzer
40-1054 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DW2AKA]
FAILURE CODE [DW2AKA]

Action level Failure code Main Pressure Variable Solenoid Output Open Circuit
Failure
L01 DW2AKA (Transmission controller system)
Details of fail-
When the controller operates the main pressure variable solenoid circuit, no current flows through the circuit.
ure
Effect of con-
Stops operation of the main pressure variable solenoid.
troller
Effect on the
Main pressure variable solenoid does not function and fuel consumption may increase.
machine
q Output state of main pressure variable solenoid is seen on monitor function. (Code: 31643 (mA))
q Controller does not operate the main pressure variable solenoid circuit until the start switch is turned to
Related infor- the OFF position.
Procedure: Start the engine and increase the transmission oil temperature to 60 °C or more, then operate
the machine in F4.

Defective main pressure
1 2. Disconnect connector M/P,PS, and connect T-adapter to the male side.
variable solenoid valve
Resistance Between M/P,PS (male) (1) and (2) 5 to 15 Ω

2. Disconnect connectors ATC3 and M/P,PS, and connect T-adapter to each female side.
2
ness Between ATC3 (female) (13) and M/P,PS (female) (2) Max. 1 Ω
Resistance
Between ATC3 (female) (38) and M/P,PS (female) (1) Max. 1 Ω
3
Circuit diagram related to main pressure variable solenoid
HD465-8, HD605-8 40-1055

FAILURE CODE [DW2AKB] 40 TROUBLESHOOTING
FAILURE CODE [DW2AKB]

Action level Failure code Main Pressure Variable Solenoid Output Ground Fault
Failure
L01 DW2AKB (Transmission controller system)
Details of fail- When the controller operates the main pressure variable solenoid circuit, too much current flows through the
ure circuit.
Effect of con-
troller
Effect on the
machine
the machine in F4.

2. Disconnect connector M/P,PS, and connect T-adapter to the male side.
1
variable solenoid valve Between M/P,PS (male) (1) and (2) 5 to 15 Ω
Resistance
Between ground and M/P,PS (male) (1) or (2) Min. 1 MΩ

Ground fault in wiring har- 2. Disconnect connectors ATC3 and M/P,PS, and connect T-adapter to the female side
2 of connector ATC3.
ness
Resistance Between ATC3 (female) (38) and ground Min. 1 MΩ

Short circuit in wiring har- 2. Disconnect connectors ATC3 and M/P,PS, and connect T-adapter to the female side
ness
Resistance Between ATC3 (female) (13) and ATC3 (female) (38) Min. 1 MΩ
4
40-1056 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DW2AKY]
FAILURE CODE [DW2AKY]

Action level Failure code Main Pressure Variable Solenoid Output Hot Short Circuit
Failure
L01 DW2AKY (Transmission controller system)
Details of fail- When the controller does not operate the main pressure variable solenoid circuit, current flows through the
ure circuit.
Effect of con-
troller
Effect on the q Failure code [15*0MW] is sensed because of low oil pressure.
machine q Transmission clutch can occur during travel.
the machine in F4.

Hot short circuit in wiring 2. Disconnect connector M/P,PS, and connect T-adapter to the female side.
harness
Voltage Between M/P,PS (female) (1) and ground Max. 4.5 V
2
HD465-8, HD605-8 40-1057

FAILURE CODE [DW2AL1] 40 TROUBLESHOOTING
FAILURE CODE [DW2AL1]

Action level Failure code Main Pressure Variable Valve Release Trouble
Failure
L01 DW2AL1 (Transmission controller system)
Details of fail- When the controller does not operate the main pressure variable solenoid circuit, the signal from its pressure
ure sensor does not respond correctly.
Effect of con- q Stops operation of the main pressure variable solenoid.
troller q Stops operation of the main flow selector solenoid.
Effect on the q Failure code [15*0MW] is sensed because of low oil pressure.
machine q Transmission clutch can occur during travel.
q Output current of the main pressure variable solenoid is seen on monitor function. (Code: 31643 (mA))
q Main pressure variable valve operation pressure is seen on monitor function. (Code: 07707 (MPa), 07708
(V))
Related infor- q Controller does not operate the main pressure variable solenoid circuit until the start switch is turned to
mation the OFF position.
the machine in F4.

1 Defective hydraulic piping Hydraulic piping may be defective. Inspect it.
1. Start the engine and raise transmission oil temperature to 60 °C or higher.

3. Insert T-adapter into connector M/P,P.
Defective main pressure 4. Turn the start switch to the ON position.
2 variable valve operation
REMARK
pressure sensor
Transmission oil temperature is seen on monitor function. (Code: 32500)
Depress the accelerator
Voltage Between M/P,P (2) and (1) 2.8 to 3.8 V
pedal.
3
40-1058 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DW2ALH]
FAILURE CODE [DW2ALH]

Action level Failure code Main Pressure Variable Valve Malfunction
Failure
L01 DW2ALH (Transmission controller system)
Details of fail- When the controller operates the main pressure variable solenoid circuit, signal from the pressure sensor of
ure main pressure variable solenoid circuit does not respond correctly.
Effect of con-
troller
Effect on the
machine
q Output current of the main pressure variable solenoid is seen on monitor function. (Code: 31643 (mA))
q Main pressure variable valve operation pressure is seen on monitor function. (Code: 07707 (MPa), 07708
(V))
Related infor- q Controller does not operate the main pressure variable solenoid circuit until the start switch is turned to
mation the OFF position.
the machine in F4.

1 variable valve operation Perform troubleshooting for failure code [DW2AL1].
pressure sensor system
HD465-8, HD605-8 40-1059

FAILURE CODE [DW2BKA] 40 TROUBLESHOOTING
FAILURE CODE [DW2BKA]

Action level Failure code Main Flow Selector Solenoid Open Circuit
Failure
L01 DW2BKA (Transmission controller system)
Details of fail-
When the controller operates the main flow selector solenoid circuit, no current flows through the circuit.
ure
q Stops operation of the main flow selector solenoid.
Effect of con-
troller
OFF position.
Effect on the
Main flow selector solenoid does not function and fuel consumption may increase.
machine
q Output state of main flow selector solenoid is seen on monitor function. (Code: 31644 (mA))
mation Procedure: Start the engine and increase the transmission oil temperature to 60 °C or more, then operate
the machine in F3.

2. Disconnect connector VOL,PS, and connect T-adapter to the male side.
Defective main flow selec-
1
tor solenoid Between VOL,PS (male) (1) and (2) 5 to 15 Ω
Resistance
Between ground and VOL,PS (male) (1) or (2) Min. 1 MΩ

2. Disconnect connectors ATC3 and VOL,PS, and connect T-adapter to each female
2
ness
Between ATC3 (female) (7) and VOL,PS (female) (1) Max. 1 Ω
Resistance
Between ATC3 (female) (23) and VOL,PS (female) (2) Max. 1 Ω
3
Circuit diagram related to main flow selector solenoid
40-1060 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DW2BKB]
FAILURE CODE [DW2BKB]

Action level Failure code Main Flow Selector Solenoid Ground Fault
Failure
L01 DW2BKB (Transmission controller system)
Details of fail-
When the controller operates main flow selector solenoid circuit, too much current flows through the circuit.
ure
Effect of con-
troller
OFF position.
Effect on the
If the machine continues to travel, fuel consumption increases.
machine
mation Procedure: Start the engine and increase the transmission oil temperature to 60 °C or more, then operate
the machine in F3.

2. Disconnect connector VOL,PS, and connect T-adapter to the male side.
1
tor solenoid Between VOL,PS (male) (1) and (2) 5 to 15 Ω
Resistance
Between ground and VOL,PS (male) (1) or (2) 1 MΩ

Ground fault in wiring har- 2. Disconnect connectors ATC3 and VOL,PS, and connect T-adapter to the female side
ness
Resistance Between ATC3 (female) (7) and ground Min. 1 MΩ

Short circuit in wiring har- 2. Disconnect connectors ATC3 and VOL,PS, and connect T-adapter to the female side
ness
Resistance Between ATC3 (female) (7) and ATC3 (female) (23) Min. 1 MΩ
4
HD465-8, HD605-8 40-1061

FAILURE CODE [DW2BKY] 40 TROUBLESHOOTING
FAILURE CODE [DW2BKY]

Action level Failure code Main Flow Selector Solenoid Hot Short Circuit
Failure
L01 DW2BKY (Transmission controller system)
Details of fail-
When the controller does not operate the main flow selector solenoid circuit, current flows through the circuit.
ure
Effect of con-
troller
OFF position.
Effect on the
Failure code [15*0MW] is sensed because of low oil pressure.
machine
Related infor-
mation
Procedure: Start the engine and increase the transmission oil temperature to 60 °C or more.

Hot short circuit in wiring 2. Disconnect connector VOL,PS, and connect T-adapter to the female side.
harness
Voltage Between VOL,PS (female) (1) and ground Max. 4.5 V
2
40-1062 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DW2BL1]
FAILURE CODE [DW2BL1]

Action level Failure code Main Flow Selector Valve Release Trouble
Failure
L01 DW2BL1 (Transmission controller system)
Details of fail- When the controller does not operate the main flow selector solenoid circuit, signal from the pressure sensor
ure of main flow selector solenoid does not respond correctly.
Effect of con-
troller
OFF position.
Effect on the
Failure code [15*0MW] is sensed because of low oil pressure.
machine

mation q Output current of the main flow selector solenoid is seen on monitor function. (Code: 31644 (mA))
q Main flow selector valve operation pressure is seen on monitor function. (Code: 77001 (MPa), 77002 (V))
Procedure: Start the engine and increase the transmission oil temperature to 60 °C or more.

1. Start the engine and raise transmission oil temperature to 60 °C or higher.

Defective main flow selec- 2. Turn the start switch to the OFF position.
2 tor solenoid operation 3. Insert T-adapter into connector VOL,P.
pressure sensor 4. Turn the start switch to the ON position.
Voltage Between VOL,P (2) and (1) 0.8 to 2.0 V
3 Troubleshoot for failure code [DW2BKB] and [DW2BKY].
tor solenoid system
4
HD465-8, HD605-8 40-1063

FAILURE CODE [DW2BLH] 40 TROUBLESHOOTING
FAILURE CODE [DW2BLH]

Action level Failure code Main Flow Selector Valve Operation Malfunction
Failure
L01 DW2BLH (Transmission controller system)
Details of fail- When the controller operates the main flow selector solenoid circuit, signal from the pressure sensor of the
ure main flow selector solenoid does not respond correctly.
Effect of con-
troller
OFF position.
Effect on the
If the machine continues to travel, fuel consumption increases.
machine
gage the body pivot pin.
Related infor-
q Output current of the main flow selector solenoid is seen on monitor function. (Code: 31644 (mA))
mation
q Main flow selector valve operation pressure is seen on monitor function. (Code: 77001 (MPa), 77002 (V))
the machine in F3.

1 Troubleshoot for failure code [DW2BL1].
tor solenoid system
40-1064 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DW35KZ]
FAILURE CODE [DW35KZ]

Action level Failure code Auto Suspension Solenoid 1 Output System Abnormality
Failure
L01 DW35KZ (Retarder and hoist controller system)
When the controller operates the circuit of automatic suspension solenoid 1, too much current flows through
Details of fail-
the circuit or no current flows through the circuit. Or current flows when the controller does not operate the cir-
ure
cuit.
q Stops operation of the automatic suspension solenoid 1 when the cause of failure is a ground error.
Effect of con-
q If the cause of failure is ground fault, the machine does not return to normal until the starting switch is
troller
turned to OFF position even when the cause of failure is eliminated.
Effect on the
Automatic suspension does not operate correctly.
machine
Related infor-
mation

2. Disconnect connector S04, and connect T-adapter to the male side.
Defective automatic sus- 3. Turn the start switch to the ON position.
1
pension solenoid 1
Between S04 (male) (1) and (2) 15 to 35 Ω
Resistance
Between ground and S04 (male) (1) or (2) Min. 1 MΩ

2
ing harness
Resistance Between BRC3 (female) (3) and BRC2 (female) (19) 15 to 35 Ω

3
ness
Resistance

2. Insert T-adapter into connector S04.
4 harness (defective contact REMARK
with power supply circuit) When the machine is unloaded, it is necessary to depress the brake pedal. (It is not nec-
essary when the machine is loaded.)
Voltage Between S04 (1) and (2) Max. 1 V
5
HD465-8, HD605-8 40-1065

FAILURE CODE [DW35KZ] 40 TROUBLESHOOTING
Circuit diagram related to automatic suspension solenoid 1
40-1066 HD465-8, HD605-8


Action level Failure code Auto Suspension Solenoid 2 Output System Abnormality
Failure
When the controller operates the circuit of automatic suspension solenoid 2, too much current flows through
Details of fail-
the circuit or no current flows through the circuit. Or current flows when the controller does not operate the cir-
ure
cuit.
q Stops operation of the automatic suspension solenoid 2 when the cause of failure is a ground error.
Effect of con-
q If the cause of failure is ground fault, the machine does not return to normal until the starting switch is
troller
Effect on the
Automatic suspension does not operate correctly.
machine
Related infor-
mation

2. Disconnect connector S05, and connect T-adapter to the male side.
Defective automatic sus- 3. Turn the start switch to the ON position.
1
pension solenoid 2
Between S05 (male) (1) and (2) 15 to 35 Ω
Resistance
Between ground and S05 (male) (1) or (2) Min. 1 MΩ

2
ing harness
Resistance Between BRC3 (female) (3) and BRC2 (female) (9) 15 to 35 Ω

3
ness
Resistance

2. Insert T-adapter into connector S05.
4 harness (defective contact REMARK
with power supply circuit) When the machine is unloaded, it is necessary to depress the brake pedal. (It is not nec-
essary when the machine is loaded.)
Voltage Between S05 (1) and (2) Max. 1 V
5
HD465-8, HD605-8 40-1067

Circuit diagram related to automatic suspension solenoid 2
40-1068 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DW4BK4]
FAILURE CODE [DW4BK4]

Action level Failure code Parking Brake Valve Release Trouble
Failure
L03 DW4BK4 (Retarder and hoist controller system)
Details of fail-
Parking brake oil pressure is sensed although the parking brake switch is set to the "PARK" position.
ure
Effect of con-
None in particular
troller
Effect on the
Parking brake does not operate.
machine
q Examine the signal from the parking brake oil pressure sensor with monitor function. (Code: 91908 (MPa),
91909 (V))
q The condition of operation between each part when parking brake operates correctly.
q When the parking brake switch is set to "PARK" position, pins 5 and 6 of parking brake switch are
connected.
Related infor-
q The parking brake safety relay R26, which is self-holding type, is actuated.
mation
q When the parking brake switch is set to TRAVEL position, pins 4 and 5 of parking brake switch are
connected. 24 V is continuously supplied from pin 3 of R26 because R26 keeps operation.
Pin 4 of parking brake switch becomes 24 V and parking brake solenoid operates.
Procedure: Turn the parking brake switch to "PARK" and start the engine.

Defective parking brake 2. Replace parking brake safety relay R26 with horn relay R09.
1 3. Turn the parking brake switch to "PARK" and start engine.
safety relay
If this failure code is removed, the parking brake safety relay is defective.

Open circuit in the parking
2 brake switch signal input Parking brake switch in
circuit Max. 1 V
Between BRC3 (29) and "PARK"
Voltage
(23) Parking brake switch in
Min. 18 V
"TRAVEL"
REMARK
If no failure is found by the above checks, the following check is not required.
Open circuit in wiring har- 1. Turn the starting switch to OFF position.
3
ness 2. Disconnect connectors PBS and BRC3, and connect T-adapter to each female side.
Resistance Between PBS (female) (4) and BRC3 (29) Max. 1Ω

2. Disconnect connectors PBS and PPSR, and connect T-adapter to each female side.
Hot short circuit inwireing 3. Turn the starting switch to ON position.
4
harness
Between PBS (female) (4) and (5) Max. 1 V
Voltage
Between PPSR (female) (2) and (1) Max. 0.5V
HD465-8, HD605-8 40-1069

FAILURE CODE [DW4BK4] 40 TROUBLESHOOTING

Defective parking brake oil
5 Parking brake switch in 0.30 to 0.85
pressure sensor
Between BRC2 (5) and "PARKING" V
Voltage
BRC1 (21) Parking brake switch in 1.25 to 1.36
"TRAVEL" V
To troubleshoot refer to TEST AND ADJUST, "PROCEDURE TO TEST PARKING
6 hydraulic circuit or parking
BRAKE OIL PRESSURE" under "TEST PARKING BRAKE OIL PRESSURE".
brake valve
40-1070 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DW4BK4]
HD465-8, HD605-8 40-1071

FAILURE CODE [DW4BK4] 40 TROUBLESHOOTING
40-1072 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DW4BMA]
FAILURE CODE [DW4BMA]

Action level Failure code Parking Brake Valve Activity Malfunction
Failure
L03 DW4BMA (Retarder and hoist controller system)
Details of fail-
Parking brake oil pressure is not detected even if the parking brake switch is set to TRAVEL position.
ure
Action of con-
None in particular
troller
Phenomenon
Parking brake is not released.
on machine
q If failure code [DHUCKX] is also displayed, perform troubleshooting for it first
q Check the signal from parking brake oil pressure sensor with monitoring function. (Code: 91908 (MPa),
Related infor-
91909 (V))
mation
Procedure: Start the engine and set the parking brake switch to TRAVEL position.
1. Turn the start switch to the position.

2. Disconnect connector R26, and replace with the same type of relay.
Defective parking brake 4. Operate the machine in F1.
1
safety relay Relay R26 is
Judgment by The machine returns to normal. defective.
replacing
relay R26 Relay R26 is
Machine does not return to normal.
normal.

2. Disconnect connectors PSR and connect T-adapter to male side.
2
solenoid Between PSR (male) (1) and (2) Approx. 15 Ω
Resistance
Between PSR (male) (1) and ground Min. 1 MΩ

2. Disconnect connector PSR and connect T-adapter to female side.
3. Set the parking brake switch to PARKING position and turn the starting switch to ON
position.
3 4. Set the parking brake switch to TRAVEL position.
solenoid system
REMARK
If check result is abnormal, proceed to next item. If no failure is found, proceed to cause 5.
Voltage Between PSR (female) (1) and (2) Min. 18 V

Open circuit in wiring har- 2. Disconnect connectors BRC3 and PBS, and connect T-adapter to female side of PBS.
4
ness
Resistance Between PBS (female) (4) and ground (solenoid resistor) Approx. 15 Ω
HD465-8, HD605-8 40-1073

FAILURE CODE [DW4BMA] 40 TROUBLESHOOTING

2. Disconnect connector PPSR, and connect T-adapter to female side.
Voltage Between PPSR (female) (3) and (1) Approx. 5 V
REMARK
5 pressure sensor power
supply system If no failure is found by the above checks, the following check is not required.
2. Disconnect connectors BRC 1 and PPSR, and connect T-adapter to each female side.
Between PPSR (female) (1) and BRC1 (female) (21) Max. 1 Ω
Resistance
Between PPSR (female) (3) and BRC1 (female) (22) Max. 1 Ω

2. Insert T-adapter into connector PPSR.
REMARK
6 If check result is abnormal, proceed to next item. If no failure is found, proceed to cause 8.
pressure sensor
Parking brake switch in 0.30 to 0.85
PARKING V
Voltage Between PPSR (2) and (1)
Parking brake switch in 1.25 to 1.36
TRAVEL V
Perform the troubleshooting referring to TEST AND ADJUST, "TEST PARKING BRAKE
7 hydraulic circuit or parking
OIL PRESSURE".
brake valve

Open circuit in wiring har- 2. Disconnect connectors BRC2 and PPSR, and connect T-adapter to each female side.
8
ness
Resistance Between PPSR (female) (2) and BRC2 (female) (5) Max. 1 Ω
Defective retarder and If no failure is found by the above checks, the retarder id hoist controller is defective.
9
hoist controller (Since this is an internal defect, troubleshooting cannot be performed.)
40-1074 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DW4BMA]
HD465-8, HD605-8 40-1075

FAILURE CODE [DW4BMA] 40 TROUBLESHOOTING
40-1076 HD465-8, HD605-8


Action level Failure code Dump Lever Kick out Solenoid Malfunction
Failure
Details of fail- No current or too much current flows when the controller operates the hoist lever kick-out solenoid circuit. Or
ure current flows through the circuit when the controller does not operate the circuit.
Effect of con-
Stops operation of the kick-out solenoid when the cause of failure is ground error.
troller
Effect on the
Hoist lever stop (between HOLD and RAISE) does not work, or remains in operation.
machine
mation Procedure: Start the engine and set the hoist lever to the "RAISE" position.

2. Disconnect connector LKO, and connect T-adapter to the male side.
Defective hoist lever
1
kick-out solenoid Between LKO (male) (1) and (2) 37 to 41 Ω
Resistance
Between LKO (male) (1) and ground Min. 1 MΩ

Open or short circuit in wir- 2. Disconnect connector BRC3, and connect T-adapter to the female side.
2
If there is no failure found by check on cause 2, this check is not required.
Open circuit in wiring har- 2. Disconnect connectors BRC3 and LKO, and connect T-adapter to each female side.
3
ness
Between BRC3 (female) (18) and LKO (female) (1) Max. 1 Ω
Resistance
Between BRC3 (female) (3) and LKO (female) (2) Max. 1 Ω

Ground fault in wiring har- 2. Disconnect connectors BRC3 and LKO, and connect T-adapter to either female side.
4
ness Between ground and BRC3 (female) (18) or LKO (female)
(1)
Short circuit in wiring har- 2. Disconnect connectors BRC3 and LKO, and connect T-adapter to either female side.
5
ness
Between BRC3 (female) (18) and (3), or between LKO

Hot short circuit in wiring 2. Disconnect connector LKO, and connect T-adapter to the female side.
harness
Voltage Between LKO (female) (1) and (2) Max. 4.5 V

Defective retarder and Hoist lever: HOLD Max. 4.5 V

7
hoist controller Voltage Between BRC3 (18) and (3) Hoist lever: Between RAISE
20 to 30 V
and detent
If there is no failure found by the previous checks, the retarder and hoist controller is
defective. (Since this is an internal defect, you cannot troubleshoot.)
HD465-8, HD605-8 40-1077

Circuit diagram related to kick out solenoid
40-1078 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DW73KA]
FAILURE CODE [DW73KA]

Action level Failure code Hoist Selector Solenoid Open Circuit
Failure
L03 DW73KA (Retarder and hoist controller system)
Details of fail-
When the controller operates the hoist selector solenoid circuit, no current flows through the circuit.
ure
Effect of con-
Stops operation of the hoist EPC valve.
troller
Effect on the
machine
Related infor-
mation gage the body pivot pin.
After the repair is completed, remove the failure code by this procedure.
Procedure: Start the engine and set the hoist lever to "HOLD", and then to "FLOAT" or "LOWER".

Defective hoist selector 2. Disconnect connector HSOL, and connect T-adapter to the male side.
1
solenoid
Resistance Between HSOL (male) (A) and (B) 30 to 70 Ω

2
Open circuit in wiring har- 2. Disconnect connectors BRC3 and HSOL, and connect T-adapter to each female side.
3
ness
Between BRC3 (female) (8) and HSOL (female) (B) Max. 1 Ω
Resistance
Between BRC3 (female) (3) and HSOL (female) (A) Max. 1 Ω


4
20 to 30 V
and detent
HD465-8, HD605-8 40-1079

FAILURE CODE [DW73KA] 40 TROUBLESHOOTING
Circuit diagram related to hoist selector solenoid
40-1080 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DW73KB]
FAILURE CODE [DW73KB]

Action level Failure code Hoist Selector Solenoid Ground Fault
Failure
L03 DW73KB (Retarder and hoist controller system)
Details of fail-
When the controller operates the hoist selector solenoid circuit, too much current flows through the circuit.
ure
q Stops operation of the hoist selector solenoid.
Effect of con- q Stops operation of the hoist EPC valve.
OFF position.
Effect on the
machine
Related infor-

2. Disconnect connector HSOL, and connect T-adapter to the male side.
Defective hoist selector
1
solenoid Between HSOL (male) (A) and (B) 30 to 70 Ω
Resistance
Between HSOL (male) (B) and ground Min. 1 MΩ

2

Ground fault in wiring har- 2. Disconnect connectors BRC3 and HSOL, and connect T-adapter to the female side of
3 HSOL.
ness
Resistance Between HSOL (female) (B) and ground Min. 1 MΩ
Short circuit in wiring har- 2. Disconnect connectors BRC3 and HSOL, and connect T-adapter to the female side of
4
ness HSOL.
Resistance Between HSOL (female) (A) and (B) Min. 1 MΩ


5
20 to 30 V
and detent
HD465-8, HD605-8 40-1081

FAILURE CODE [DW73KB] 40 TROUBLESHOOTING
40-1082 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DW73KY]
FAILURE CODE [DW73KY]

Action level Failure code Hoist Selector Solenoid Hot Short Circuit
Failure
L03 DW73KY (Retarder and hoist controller system)
Details of fail-
When the controller does not operate the hoist selector solenoid circuit, current flows through circuit.
ure
Effect of con-
Stops operation of the hoist EPC valve.
troller
Effect on the
machine
Related infor-

Hot short circuit in wiring 2. Disconnect connector HSOL, and connect T-adapter to the female side.
harness
Voltage Between HSOL (female) (B) and (A) Max. 4.5 V


2
20 to 30 V
and detent
HD465-8, HD605-8 40-1083


Action level Failure code Brake Cooling Valve Solenoid Malfunction (Rear)
Failure
Details of fail- When the controller operates the solenoid circuit of the brake cooling valve, no current flows or too much cur-
ure rent flows through the circuit. Or current flows when the controller does not operate the circuit.
Effect of con-
Stops operation of the BCV solenoid when the cause of failure is a ground error.
troller
Effect on the
No symptom appear or the retarder may become too hot because of the inability to cool.
machine

2. Disconnect connector BCVR2, and connect T-adapter to the male side.
1 Defective BCV solenoid
Between BCVR2 (male) (1) and (2) 20 to 60 Ω
Resistance
Between ground and BCVR2 (male) (1) or (2) Min. 1 MΩ

2. Remove connector D15, and connect T-adapter to diode.
Defective diode (internal Measure it with diode range of multimeter.
2
open circuit or short circuit)
Between D15 (male) (1) (+) and (2) (-) No continuity
Continuity
Between D15 (male) (2) (+) and (1) (-) Continuity

3
If there is no failure found by the check on cause 3, this check is not required.
Open circuit in wiring har- 2. Disconnect connectors BRC3 and BCVR2, and connect T-adapter to the female side.
4
ness
Between BRC3 (female) (17) and BCVR2 (female) (1) Max. 1 Ω
Resistance
Between BRC3 (female) (13) and BCVR2 (female) (2) Max. 1 Ω

2. Disconnect connectors BRC3, BCVR2, and D15, and connect T-adapter to the female
Ground fault in wiring har- side of BRC3 or BCUR2.
5
ness
Between ground and BRC3 (female) (17) or BCVR2
(female) (1)
If there is no failure found by the check on cause 3, this check is not required.
Short circuit in wiring har- 2. Disconnect connectors BRC3 and BCVR2, and connect T-adapter to either female
6 side.
ness
Between BRC3 (female) (17) and (13), or between BCVR2

Hot short circuit in wiring 2. Disconnect connector BCVR2, and connect T-adapter to the female side.
harness
Voltage Between BCVR2 (female) (1) and (2) Max. 4.5 V
40-1084 HD465-8, HD605-8


Retarder and front brake:
Defective retarder and Max. 4.5 V
8 Between BRC3 (17) and ON
(13) Retarder and front brake:
20 to 30 V
OFF
Circuit diagram related to rear brake cooling valve solenoid
HD465-8, HD605-8 40-1085

FAILURE CODE [DW7BKB] 40 TROUBLESHOOTING
FAILURE CODE [DW7BKB]

Action level Failure code Radiator Fan Reverse Solenoid Ground Fault
Failure
L01 DW7BKB (Transmission controller system)
Details of fail-
When the controller operates the radiator fan reverse solenoid, too much current flows through the circuit.
ure
q Stops operation of the radiator fan reverse solenoid.
Effect of con-
troller
OFF position.
Effect on the
Radiator fan does not rotate in the opposite direction.
machine
q Examine the output condition to radiator fan reverse solenoid with monitor function. (Code: 03705)
Related infor-
mation
Procedure: Turn the start switch to ON position and set radiator fan in reverse mode.

1
reverse solenoid Between RSS (male) (1) and (2) 35 to 45 Ω
Resistance
Between ground and RRS (male) (1) or (2) Min. 1 MΩ

Open or short circuit in wir- 2. Disconnect connectors ATC2 and ATC3, and connect T-adapter to each female side.
2
ing harness Between ATC2 (female) (19) and ATC3 (female) (23)

Ground fault in wiring har- 2. Disconnect connectors ATC2 and RSS, and connect T-adapter to either female side.
3
ness Between ground and ATC2 (female) (19) or RSS (female)
(1)
Short circuit in wiring har- 2. Disconnect connectors ATC2, ATC3, and RRS, and connect T-adapter to any female
4 side.
ness
Between ATC2 (female) (19) and ATC3 (female) (23) or
between RRS (female) (1) and (2)
5
Circuit diagram related to radiator fan reverse rotation solenoid
40-1086 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DW7BKY]
FAILURE CODE [DW7BKY]

Action level Failure code Radiator Fan Reverse Solenoid Hot Short Circuit
Failure
L01 DW7BKY (Transmission controller system)
Details of fail- When the controller does not operate the radiator fan reverse solenoid circuit, current flows through the cir-
ure cuit.
Effect of con-
Stops operation of the radiator fan reverse solenoid.
troller
Effect on the Radiator fan continues rotation in reverse direction. If this failure occurs while the fan turns in the normal
machine direction, damage to the fan may occur because of changes of rotation direction.
Related infor-
mation

Hot short circuit in wiring 2. Disconnect connector RRS, and connect T-adapter to the female side.
harness
Voltage Between RSS (female) (1) and (2) Max. 4.5 V
2
HD465-8, HD605-8 40-1087

FAILURE CODE [DW7BKZ] 40 TROUBLESHOOTING
FAILURE CODE [DW7BKZ]

Action level Failure code Radiator Fan Reverse Solenoid Open Circuit or Hot Short Circuit
Failure
L01 DW7BKZ (Transmission controller system)
Details of fail- When the controller does not operate the radiator fan reverse solenoid circuit, voltage is 2.5 V and above or
ure below 7.0 V.
Effect of con-
None in particular
troller
Effect on the
Radiator fan does not rotate in the reverse direction.
machine
Related infor-
mation

1
reverse solenoid Between RSS (male) (1) and (2) 35 to 45 Ω
Resistance
Between ground and RRS (male) (1) or (2) Min. 1 MΩ

2
2. Disconnect connectors ATC2, ATC3, and RRS, and connect T-adapter to each female
3 side.
ness
Between ATC2 (female) (19) and RRS (female) (1) Max. 1 Ω
Resistance
Between ATC3 (female) (23) and RRS (female) (2) Max. 1 Ω

Hot short circuit in wiring 2. Disconnect connector RRS, and connect T-adapter to the female side.
harness
Voltage Between RSS (female) (1) and (2) Max. 4.5 V
5
40-1088 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DW7NKZ]
FAILURE CODE [DW7NKZ]

Action level Failure code S/T Pump Selector Solenoid Malfunction
Failure
L01 DW7NKZ (Retarder and hoist controller system)
Details of fail- When the controller operates the steering pump selector solenoid circuit, no current flows or too much current
ure flows through the circuit. Or current flows when the controller does not drive the circuit.
q Stops operation of the steering pump selector solenoid when the cause of failure is a ground error.
Effect of con-
troller
OFF position.
Effect on the
Dump body raise speed becomes slow or the dump body raise and lower speed becomes fast.
machine
Related infor-
Procedure: Start the engine and raise the body.

2. Disconnect connector SCS, and connect T-adapter to the male side.
Defective steering pump
1
selector solenoid Between SCS (male) (1) and (2) 20 to 60 Ω
Resistance
Between ground and SCS (male) (1) or (2) Min. 1 MΩ

2. Disconnect connectors BRC2, BRC3, and SCS, and connect T-adapter to the female
Open or short circuit in wir- side of BRC2 and BRC3.
2
ing harness
Between BRC3 (female) (3) and BRC2 (female) (18)
2. Disconnect connectors BRC2, BRC3, and SCS, and connect T-adapter to each
3 female side.
ness
Between BRC2 (female) (18) and SCS (female) (1) Max. 1 Ω
Resistance
Between BRC3 (female) (3) and SCS (female) (2) Max. 1 Ω

Ground fault in wiring har- 2. Disconnect connectors SCS and BRC2, and connect T-adapter to either female side.
4
ness Between ground and BRC2 (female) (18) or SCS (female)
(1)
Short circuit in wiring har- 2. Disconnect connectors SCS, BRC2, and BRC3, and connect T-adapter to the female
5 side of BRC2 and BRC3, or SCS.
ness
Between BRC2 (female) (18) and BRC3 (3), or between
SCS (female) (1) and (2)

Hot short circuit in wiring 2. Disconnect connector SCS, and connect T-adapter to the female side.
harness
Voltage Between SCS (female) (1) and (2) Max. 4.5 V
HD465-8, HD605-8 40-1089

FAILURE CODE [DW7NKZ] 40 TROUBLESHOOTING

BRC3 (3) Hoist lever: RAISE 20 to 30 V
Circuit diagram related to steering pump selector solenoid
40-1090 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DWD6KA]
FAILURE CODE [DWD6KA]

Action level Failure code Steering Pump Lockout Solenoid Failure
Failure
L03 DWD6KA (Transmission controller system)
Details of fail- When the controller does not drive the steering pump lockout solenoid circuit, voltage is 2.5 V and above or
ure below 7.0 V.
Effect of con-
troller
Effect on the q Machine lockout function cannot be activated.
machine q If the machine lockout function is working, the steering returns to the operation state.
q Check the output state of the steering pump lockout solenoid (ON/OFF) with monitoring function. (Code:

2. Disconnect connector SPCS, and connect T-adapter to male side.
1
lockout solenoid Between SPCS (male) (1) and (2) 10 to 30 Ω
Resistance
Between ground and SPCS (male) (1) or (2) Min. 1 MΩ

2
Solenoid coil resistance
2. Disconnect connectors ATC2, ATC3, and SPCS, and connect T-adapter to each
3 female side.
ness
Between ATC2 (female) (8) and SPCS (female) (1) Max. 1 Ω
Resistance
Between ATC3 (female) (3) and SPCS (female) (2) Max. 1 Ω

Hot short circuit in wiring 2. Disconnect connector SPCS, and connect T-adapter to female side.
harness
Voltage Between SPCS (female) (1) and (2) Max. 4.5 V
Defective transmission If no failure is found by preceding checks, the transmission controller is defective. (Since
5
Circuit diagram related to steering pump lockout solenoid
HD465-8, HD605-8 40-1091

FAILURE CODE [DWD6KB] 40 TROUBLESHOOTING
FAILURE CODE [DWD6KB]

Action level Failure code Steering Pump Lockout Solenoid Ground Fault
Failure
L03 DWD6KB (Transmission controller system)
Details of fail- When the controller drives the steering pump lockout solenoid circuit, excessive current flows through the cir-
ure cuit.
q Stops driving the steering pump lockout solenoid.
Effect of con- q Determines that conditions for activating the machine lockout function are not established.

2. Disconnect connector SPCS, and connect T-adapter to male side.
1
lockout solenoid Between SPCS (male) (1) and (2) 10 to 30 Ω
Resistance
Between ground and SPCS (male) (1) or (2) Min. 1 MΩ

2

2. Disconnect connectors ATC2, ATC3, and SPCS, and connect T-adapter to each
3
ness
Between ground and ATC2 (female) (8) or SPCS (female)
(1)
Short circuit in wiring har- 2. Disconnect connectors ATC2, ATC3, and SPCS, and connect T-adapter to any female
4 side.
ness
Voltage Min. 1 MΩ
between SPCS (female) (1) and (2)
5
40-1092 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DWD6KB]
HD465-8, HD605-8 40-1093

FAILURE CODE [DWD6KY] 40 TROUBLESHOOTING
FAILURE CODE [DWD6KY]

Action level Failure code Steering Pump Lockout Solenoid Hot Short
Failure
L03 DWD6KY (Transmission controller system)
Details of fail- When the controller does not drive the steering pump lockout solenoid circuit, current flows through the cir-
ure cuit.
Effect of con-
troller
Effect on the
The discharged pressure of the steering pump is always cut, and the steering wheel becomes heavy.
machine

Hot short circuit in wiring 2. Disconnect connector SPCS, and connect T-adapter to female side.
harness
Voltage Between SPCS (female) (1) and (2) Max. 4.5 V
2
40-1094 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DWD6MA]
FAILURE CODE [DWD6MA]

Action level Failure code Steering Pump Lockout Solenoid Malfunction
Failure
L03 DWD6MA (Transmission controller system)
Details of fail- When the controller drives the steering pump lockout solenoid circuit, signal from the steering oil pressure
ure sensor does not respond correctly.
Effect of con-
troller
03705)
Related infor-
q Steering oil pressure can be checked by the monitoring function. (Code: 95302 (MPa), 95303 (V))
mation


2. Insert T-adapter into connector H01.
Defective steering oil pres- 3. Turn the starting switch to ON position.
2
sure sensor
0.30 to 0.56
Voltage Between H01 (C) and (A)
V
3
HD465-8, HD605-8 40-1095

FAILURE CODE [DWD7K4] 40 TROUBLESHOOTING
FAILURE CODE [DWD7K4]

Action level Failure code Steering/Hoist Pump Lockout Solenoid becomes stuck
Failure
L03 DWD7K4 (Transmission controller system)
Details of fail- When the controller does not drive the steering/hoist pump lockout solenoid circuit, signal from the steer-
ure ing/hoist pump oil pressure sensor does not respond correctly.
Effect of con-
None in particular
troller
Phenomenon
The discharged pressure of the steering/hoist pump is always cut, and the steering wheel becomes heavy.
on machine
q Check the output state of the steering/hoist pump lockout solenoid (ON/OFF) with monitoring function.
(Code: 03705)
Related infor- q Steering/hoist pump oil pressure can be checked by the monitoring function. (Code: 95307 (MPa), 95308
mation (V))


2. Insert T-adapter into connector WPP.
Defective steering/hoist 3. Start the engine.
2
0.56 to 4.42
Voltage Between WPP (C) and (A)
V
3
40-1096 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DWD7KA]
FAILURE CODE [DWD7KA]

Action level Failure code Steering/Hoist Pump Lockout Solenoid Failure
Failure
L03 DWD7KA (Transmission controller system)
Details of fail- When the controller does not drive the steering/hoist pump lockout solenoid circuit, voltage is 2.5 V and
ure above or below 7.0 V.
Effect of con-
troller

2. Disconnect connector WPCS, and connect T-adapter to male side.
Defective steering/hoist
1
pump lockout solenoid Between WPCS (male) (1) and (2) 10 to 30 Ω
Resistance
Between ground and WPCS (male) (1) or (2) Min. 1 MΩ

2
2. Disconnect connectors ATC2, ATC3, and WPCS, and connect T-adapter to each
3 female side.
ness
Between ATC2 (female) (9) and SPCS (female) (1)
Between ATC3 (female) (13) and SPCS (female) (2)

Hot short circuit in wiring 2. Disconnect connector WPCS, and connect T-adapter to female side.
harness
Voltage Between WPCS (female) (1) and (2) Max. 4.5 V
5
Circuit diagram related to steering/hoist pump lockout solenoid
HD465-8, HD605-8 40-1097

FAILURE CODE [DWD7KB] 40 TROUBLESHOOTING
FAILURE CODE [DWD7KB]

Action level Failure code Steering/Hoist Pump Lockout Solenoid Ground Fault
Failure
L03 DWD7KB (Transmission controller system)
Details of fail- When the controller drives the steering/hoist pump lockout solenoid circuit, excessive current flows through
ure the circuit.
q Stops driving the steering/hoist pump lockout solenoid.
Effect of con- q Determines that conditions for activating the machine lockout function are not established.

2. Disconnect connector WPCS, and connect T-adapter to male side.
Defective steering/hoist
1
pump lockout solenoid Between WPCS (male) (1) and (2) 10 to 30 Ω
Resistance
Between ground and WPCS (male) (1) or (2) Min. 1 MΩ

2

2. Disconnect connectors ATC2, ATC3, and WPCS, and connect T-adapter to each
3
ness
Between ground and ATC2 (female) (9) or WPCS (female)
(1)
Short circuit in wiring har- 2. Disconnect connectors ATC2, ATC3, and WPCS, and connect T-adapter to any
4 female side.
ness
Voltage Min. 1 MΩ
between WPCS (female) (1) and (2)
5
40-1098 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DWD7KB]
HD465-8, HD605-8 40-1099

FAILURE CODE [DWD7KY] 40 TROUBLESHOOTING
FAILURE CODE [DWD7KY]

Action level Failure code Steering/Hoist Pump Lockout Solenoid Hot Short
Failure
L03 DWD7KY (Transmission controller system)
Details of fail- When the controller does not drive the steering/hoist pump lockout solenoid circuit, current flows through the
ure circuit.
Effect of con-
troller
Effect on the
The discharged pressure of the steering/hoist pump is always cut, and the steering wheel becomes heavy.
machine

Hot short circuit in wiring 2. Disconnect connector WPCS, and connect T-adapter to female side.
harness
Voltage Between WPCS (female) (1) and (2) Max. 4.5 V
2
40-1100 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DWD7MA]
FAILURE CODE [DWD7MA]

Action level Failure code Steering/Hoist Pump Lockout Solenoid Malfunction
Failure
L03 DWD7MA (Transmission controller system)
Details of fail- When the controller drives the steering/hoist pump lockout solenoid circuit, signal from the steering/hoist
ure pump oil pressure sensor does not respond correctly.
Effect of con-
troller
(Code: 03705)
Related infor- q Steering/hoist pump oil pressure can be checked by the monitoring function. (Code: 95307 (MPa), 95308
mation (V))


2. Insert T-adapter into connector WPP.
Defective steering/hoist 3. Turn the starting switch to ON position.
2
0.30 to 0.56
Voltage Between WPP (C) and (A)
V
3
HD465-8, HD605-8 40-1101

FAILURE CODE [DWNDKZ] 40 TROUBLESHOOTING
FAILURE CODE [DWNDKZ]

Action level Failure code ABS Cut valve solenoid (Front) circuit Abnormality
Failure
L03 DWNDKZ (ABS controller system)
Details of fail- When the controller drives the ABS cut valve (front) circuit, no current flows or excessive current flows
ure through the circuit. Or current flows when the controller does not drive the circuit.
Effect of con-
troller

2. Disconnect connector CVF, and connect T-adapter to male side.
Defective ABS cut valve
1
(front) Between CVF (male) (1) and (2) 10 to 30 Ω
Resistance
Between CVF (male) (1) and ground Min. 1 MΩ

Open or short circuit in wir- 2. Disconnect connectors OPC2 and OPC3, and connect T-adapter to each female side.
2
ing harness Between OPC2 (female) (19) and OPC3 (female) (3)
2. Disconnect connectors OPC2, OPC3, and CVF, and connect T-adapter to each
3 female side.
ness
Between OPC2 (female) (19) and CVF (female) (1) Max. 1 Ω
Resistance
Between OPC3 (female) (3) and CVF (female) (2) Max. 1 Ω

Ground fault in wiring har- 2. Disconnect connectors OPC2 and CVF, and connect T-adapter to either female side.
4
ness Between ground and OPC2 (female) (19) or CVF (female)
(1)
Short circuit in wiring har- 2. Disconnect connectors OPC2, OPC3, and CVF, and connect T-adapter to female side
5 of OPC2 and OPC3, or CVF.
ness
Between OPC2 (female) (19) and OPC3 (3), or between
Voltage Min. 1 MΩ
CVF (female) (1) and (2)

Hot short circuit in wiring 2. Disconnect connector CVF, and connect T-adapter to female side.
harness
Voltage Between CVF (female) (1) and (2) Max. 4.5 V
40-1102 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DWNDKZ]
Circuit diagram related to ABS cut valve (front)
HD465-8, HD605-8 40-1103

FAILURE CODE [DWNDMA] 40 TROUBLESHOOTING
FAILURE CODE [DWNDMA]

Action level Failure code ABS Cut valve solenoid (Front) Abnormality
Failure
L03 DWNDMA (ABS controller system)
Even if the controller drives the ABS cut valve (front) circuit, the ABS cut valve pressure switch (front) detects
Details of fail-
the oil pressure (malfunction), or even if the brake is operated when the controller does not drive, the ABS cut
ure
valve pressure switch (front) does not detect the oil pressure (release trouble).
Effect of con-
q If the cause of failure is a malfunction, the machine does not return to normal until the starting switch is
troller
machine q Font brake cut may not be operating normally.
mation Procedure: Start the engine and perform the ABS system check.

Defective ABS cut valve 2. Disconnect connector CVSF, and connect T-adapter to male side.
1
pressure switch (front)
Resistance Between CVSF (male) (A) and (B) Min. 1 MΩ

2. Disconnect connectors OPC1 and CVSF, and connect T-adapter to each female side.
2
ness Between OPC1 (female) (23) and CVSF (female) (A) Max. 1 Ω
Resistance
Between OPC1 (female) (10) and CVSF (female) (B) Max. 1 Ω

Ground fault in wiring har- 2. Disconnect connectors OPC1 and CVSF, and connect T-adapter to either female side.
3
ness Between ground and OPC1 (female) (23) or CVSF (female)
(A)

Short circuit in wiring har- 2. Disconnect connectors OPC1 and CVSF, and connect T-adapter to either female side.
4
ness Between OPC1 (female) (23) and (10), or between CVSF
Voltage Min. 1 MΩ
Defective front brake
5 hydraulic circuit or ABS cut Check and troubleshoot the front brake hydraulic circuit or ABS cut valve (front).
valve (front)
40-1104 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DWNDMA]
Circuit diagram related to ABS cut valve pressure switch (front)
HD465-8, HD605-8 40-1105

FAILURE CODE [DWNEKZ] 40 TROUBLESHOOTING
FAILURE CODE [DWNEKZ]

Action level Failure code ABS Cut valve solenoid (Rear) circuit Abnormality
Failure
L03 DWNEKZ (ABS controller system)
Details of fail- When the controller drives the ABS cut valve (rear) circuit, no current flows or excessive current flows through
ure the circuit. Or current flows when the controller does not drive the circuit.
Effect of con-
troller

2. Disconnect connector CVR, and connect T-adapter to male side.
Defective ABS cut valve
1
(rear) solenoid Between CVR (male) (2) and (1) 10 to 30 Ω
Resistance
Between CVR (male) (2) and ground Min. 1 MΩ

Open or short circuit in wir- 2. Disconnect connectors OPC2 and OPC3, and connect T-adapter to each female side.
3
2. Disconnect connectors OPC2, OPC3, and CVR, and connect T-adapter to each
3 female side.
ness
Between OPC2 (female) (9) and CVR (female) (2) Max. 1 Ω
Resistance
Between OPC3 (female) (13) and CVR (female) (1) Max. 1 Ω

Ground fault in wiring har- 2. Disconnect connectors OPC2 and CVR, and connect T-adapter to either female side.
4
ness Between ground and OPC2 (female) (9) or CVR (female)
(2)
Short circuit in wiring har- 2. Disconnect connectors OPC2, OPC3, and CVR, and connect T-adapter to female side
5 of OPC2 and OPC3, or CVR.
ness
Voltage Min. 1 MΩ
CVR (female) (2) and (1)

Hot short circuit in wiring 2. Disconnect connector CVR, and connect T-adapter to female side.
harness
Voltage Between CVR (female) (2) and (1) Max. 4.5 V
40-1106 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DWNEKZ]
Circuit diagram related to ABS cut valve (rear)
HD465-8, HD605-8 40-1107

FAILURE CODE [DWNEMA] 40 TROUBLESHOOTING
FAILURE CODE [DWNEMA]

Action level Failure code ABS Cut valve solenoid (Rear) Abnormality
Failure
L03 DWNEMA (ABS controller system)
Even if the controller drives the ABS cut valve (rear) circuit, the ABS cut valve pressure switch (rear) detects
Details of fail-
the oil pressure (malfunction), or even if the brake is operated when the controller does not drive, the ABS cut
ure
valve pressure switch (rear) does not detect the oil pressure (release trouble).
Effect of con-
q If the cause of failure is a malfunction, the machine does not return to normal until the starting switch is
troller
machine q Font brake cut may not be operating normally.
mation Procedure: Start the engine and perform the ABS system check.

Defective ABS cut valve 2. Disconnect connector CVSR, and connect T-adapter to male side.
1
pressure switch (rear)
Resistance Between CVSR (male) (A) and (B) Min. 1 MΩ

2. Disconnect connectors OPC1 and CVSR, and connect T-adapter to each female side.
2
ness Between OPC1 (female) (17) and CVSR (female) (A) Max. 1 Ω
Resistance
Between OPC1 (female) (10) and CVSR (female) (B) Max. 1 Ω

2. Disconnect connectors OPC1 and CVSR, and connect T-adapter to either female
3
ness
Between ground and OPC1 (female) (17) or CVSR
(female) (A)

2. Disconnect connectors OPC1 and CVSR, and connect T-adapter to either female
4
ness
Between OPC1 (female) (17) and (10), or between CVSR
Voltage Min. 1 MΩ
Defective rear brake
6 hydraulic circuit or ABS cut Check and troubleshoot the rear brake hydraulic circuit or ABS cut valve (rear).
valve (rear)
40-1108 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DWNEMA]
Circuit diagram related to ABS cut valve pressure switch (rear)
HD465-8, HD605-8 40-1109

FAILURE CODE [DWNMKZ] 40 TROUBLESHOOTING
FAILURE CODE [DWNMKZ]

Action level Failure code Shut off Valve Output System Abnormality
Failure
L01 DWNMKZ (Retarder and hoist controller system)
Details of fail- When the controller operates the KTCS shut-off valve circuit, no current flows or too much current flows
ure through the circuit. Or current flows when the controller does not operate the circuit.
Effect of con-
troller
Effect on the
KTCS does not work.
machine

Defective KTCS shut-off
1
valve Between TCS2 (male) (1) and (2) 10 to 30 Ω
Resistance
Between TCS2 (male) (1) and ground Min. 1 MΩ

2
ing harness Between BRC2 (female) (28) and BRC3 (female) (23)
3 female side.
ness
Resistance

Ground fault in wiring har- 2. Disconnect connectors BRC2 and TCS2, and connect T-adapter to either female side.
4
ness Between ground and BRC2 (female) (28) or TCS2 (female)
(1)
Short circuit in wiring har- 2. Disconnect connectors BRC2, BRC3, and TCS2, and connect T-adapter to the female
5 side of BRC2 and BRC3, or TCS2.
ness
between TCS2 (female) (1) and (2)

harness
Voltage Between TCS2 (female) (1) and (2) Max. 4.5 V
7
40-1110 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DWNMKZ]
Circuit diagram related to KTCS shut-off valve
HD465-8, HD605-8 40-1111

FAILURE CODE [DX11K4] 40 TROUBLESHOOTING
FAILURE CODE [DX11K4]

Action level Failure code Retarder Valve Release Trouble (Rear)
Failure
L03 DX11K4 (Retarder and hoist controller system)
Details of fail-
Retarder oil pressure is sensed when the controller does not operate the retarder valve solenoid (rear) circuit.
ure
q Continues control of the retarder control lever.
q Continues control of the over speed protection retarder.
Effect of con- q Continues ARSC controls.
troller q Continues KTCS controls.
OFF position.
Effect on the Retarder (rear) does not operate correctly. (Although the retarder control lever is moved back, retarder (rear)
machine is not released.)
q Examine the signal from the retarder oil pressure sensor (rear) with monitor function (Code: 91910 (MPa),
91912 (V))
Related infor-
q If failure code [DX11KY] is shown, troubleshoot for [DX11KY] first.
mation
Procedure: Start the engine and release the retarder control lever.

Defective retarder (rear) q Inspect and troubleshoot the retarder (rear) hydraulic piping or retarder valve (rear).
1 hydraulic circuit or retarder q To troubleshoot refer to TEST AND ADJUST, "PROCEDURE TO TEST PARKING
valve (rear) BRAKE OIL PRESSURE".

Defective retarder oil pres-
2 0.30 to 0.59
sure sensor (rear) Retarder control lever: OFF
Between BRC1 (19) and V
Voltage
(21) 1.09 to 1.26
V

Defective retarder and Retarder control lever: OFF Max. 4.5 V
(13) Retarder control lever: ON 20 to 30 V
40-1112 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DX11K4]
Circuit diagram related to retarder valve (rear)
HD465-8, HD605-8 40-1113

FAILURE CODE [DX11KA] 40 TROUBLESHOOTING
FAILURE CODE [DX11KA]

Action level Failure code Retarder Valve Output Open Circuit (Rear)
Failure
L03 DX11KA (Retarder and hoist controller system)
Details of fail-
When the controller operates the retarder valve (rear) circuit, no current flows.
ure
Effect of con- q Cancels ARSC controls.
troller q Continues KTCS controls.
OFF position.
Effect on the q Retarder (rear) does not work.
machine q ARSC does not work.
mation Procedure: Start the engine and pull the retarder control lever.

Defective retarder valve 2. Disconnect connector REVR, and connect T-adapter to the male side.
1
(rear)
Resistance Between REVR (male) (1) and (2) 10 to 30 Ω

2
If there is no failure found by the previous checks, this check is not required
Open circuit in wiring har- 2. Disconnect connectors BRC3 and REVR, and connect T-adapter to each female side.
3
ness
Between BRC3 (female) (37) and REVR (female) (1) Max. 1 Ω
Resistance
Between BRC3 (female) (13) and REVR (female) (2) Max. 1 Ω

40-1114 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DX11KA]
Circuit diagram related to retarder valve open circuit (rear)
HD465-8, HD605-8 40-1115

FAILURE CODE [DX11KB] 40 TROUBLESHOOTING
FAILURE CODE [DX11KB]

Action level Failure code Retarder Valve Output Ground Fault (Rear)
Failure
L03 DX11KB (Retarder and hoist controller system)
Details of fail-
When the controller operates the retarder valve (rear) circuit, too much current flows.
ure
q Stops operation of the retarder valve (rear).
Effect of con-
q Cancels ARSC controls.
troller
q Continues KTCS controls.
OFF position.
Effect on the q Retarder (rear) does not work.
mation Procedure: Start the engine and pull the retarder control lever.

2. Disconnect connector REVR, and connect T-adapter to the male side.
Defective retarder valve
1
(rear) Between REVR (male) (1) and (2) 10 to 30 Ω
Resistance
Between REVR (male) (1) and ground Min. 1 MΩ

2

Ground fault in wiring har- 2. Disconnect connectors BRC3 and REVR, and connect T-adapter to the female side of
3 REVR.
ness
Resistance Between REVR (female) (1) and ground Min. 1 MΩ
Short circuit in wiring har- 2. Disconnect connectors BRC3 and REVR, and connect T-adapter to either female
4 side.
ness
Between BRC3 (female) (37) and (13), or between REVR
Value Min. 1 MΩ

40-1116 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DX11KB]
Circuit diagram related to retarder valve ground fault (rear)
HD465-8, HD605-8 40-1117

FAILURE CODE [DX11KY] 40 TROUBLESHOOTING
FAILURE CODE [DX11KY]

Action level Failure code Retarder Valve Output Hot Short Circuit (Rear)
Failure
L03 DX11KY (Retarder and hoist controller system)
Details of fail-
When the controller does not operate the retarder valve (rear) circuit, current flows through the circuit.
ure
Effect of con- q Continues control of the over speed protection retarder.
troller q Cancels ARSC controls.
Effect on the q Retarder (rear) does not operate correctly.
mation Procedure: Start the engine and release the retarder control lever.

Hot short circuit in wiring 2. Disconnect connector REVR, and connect T-adapter to the female side.
harness
Voltage Between REVR (female) (1) and (2) Max. 4.5 V

Circuit diagram related to retarder valve hot short circuit (rear)
40-1118 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DX11MA]
FAILURE CODE [DX11MA]

Action level Failure code Retarder Valve Malfunction (Rear)
Failure
L03 DX11MA (Retarder and hoist controller system)
Details of fail-
Retarder oil pressure is not sensed when the controller operates the retarder valve solenoid (rear) circuit.
ure
Effect of con- q Continues control of the over speed protection retarder.
troller q Continues ARSC controls.
Effect on the
Retarder (rear) does not operate correctly.
machine
q Examine the signal from the retarder oil pressure sensor (rear) with monitor function (Code: 91910 (MPa),
Procedure: Start the engine and pull the retarder control lever.

Defective retarder (rear) q Inspect and troubleshoot the retarder (rear) hydraulic piping or retarder valve (rear).
1 hydraulic circuit or retarder q To troubleshoot refer to TEST AND ADJUST, "PROCEDURE TO TEST PARKING
valve (rear) BRAKE OIL PRESSURE".

Defective retarder oil pres-
2 0.30 to 0.59
sure sensor (rear) Retarder control lever: OFF
Between BRC1 (19) and V
Voltage
(21) 1.09 to 1.26
V

HD465-8, HD605-8 40-1119

FAILURE CODE [DX11MA] 40 TROUBLESHOOTING
Circuit diagram related to retarder valve malfunction (rear)
40-1120 HD465-8, HD605-8


Action level Failure code Hoist EPC Solenoid Open Circuit
Failure
Details of fail-
When the controller operates the hoist EPC valve circuit, no current flows through the circuit.
ure
q Stops operation of the hoist EPC valve.
Effect of con-
troller
OFF position.
Effect on the
machine
mation
q Examine the output current value to the hoist EPC valve with monitor function. (Code: 45601)
Procedure: Start the engine and set the hoist lever to any position other than the "RAISE" position.

2. Disconnect connector HEPC, and connect T-adapter to the male side.
1 Defective hoist EPC valve
Between HEPC (male) (1) and (2) 10 to 30 Ω
Resistance
Between HEPC (male) (1) and ground Min. 1 MΩ

2
Open circuit in wiring har- 2. Disconnect connectors BRC3 and HEPC, and connect T-adapter to each female side.
3
ness
Between BRC3 (female) (5) and HEPC (female) (1) Max. 1 Ω
Resistance
Between BRC3 (female) (3) and HEPC (female) (2) Max. 1 Ω

4
Hoist lever: FLOAT 20 to 30 V
HD465-8, HD605-8 40-1121

Circuit diagram related to hoist EPC valve
40-1122 HD465-8, HD605-8


Action level Failure code Hoist EPC Solenoid Ground Fault
Failure
Details of fail-
When the controller operates the hoist EPC valve circuit, too much current flows through the circuit.
ure
Effect of con-
troller
OFF position.
Effect on the
machine
mation

2. Disconnect connector HEPC, and connect T-adapter to the male side.
1 Defective hoist EPC valve
Between HEPC (male) (1) and (2) 10 to 30 Ω
Resistance
Between HEPC (male) (1) and ground Min. 1 MΩ

2

Ground fault in wiring har- 2. Disconnect connectors BRC3 and HEPC, and connect T-adapter to the female side of
3 HEPC.
ness
Resistance Between HEPC (female) (1) and ground Min. 1 MΩ
Short circuit in wiring har- 2. Disconnect connectors BRC3 and HEPC, and connect T-adapter to the female side of
4
ness HEPC.
Resistance Between HEPC (female) (1) and (2) Min. 1 MΩ

5
HD465-8, HD605-8 40-1123

40-1124 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DX13KY]

Action level Failure code Hoist EPC Solenoid Hot Short Circuit
Failure
Details of fail-
When the controller does not operate the hoist EPC valve circuit, current flows through the circuit.
ure
Effect of con-
troller
OFF position.
Effect on the
You cannot perform Hold Control. (It is not possible to raise or lower the dump body.)
machine
mation

Hot short circuit in wiring 2. Disconnect connector HEPC, and connect T-adapter to the female side.
harness
Voltage Between HEPC (female) (1) and (2) Max. 4.5 V

2
HD465-8, HD605-8 40-1125


Action level Failure code Radiator Fan Pump EPC Solenoid Open Circuit
Failure
L03 DX16KA (Transmission controller system)
Details of fail-
When the controller operates the radiator fan pump EPC valve circuit, no current flows through the circuit.
ure
Effect of con- Although the cause of failure is eliminated, the machine is not normal until the start switch is turned to the
troller OFF position.
Effect on the
Radiator fan turns at its maximum speed and fuel consumption may increase.
machine
mation q Output state of the radiator fan pump EPC valve is seen on monitor function. (Code: 41400 (mA))

2. Disconnect connector RPE, and connect T-adapter to the male side.
Radiator fan pump
1
Defective EPC valve Between RPE (male) (1) and (2) 5 to 10 Ω
Resistance
Between ground and RPE (male) (1) or (2) Min. 1 MΩ

Open or short circuit in wir- 2. Disconnect connector ATC3, and connect T-adapter to the female side.
2
ing harness Between ATC3 (female) (18) and (3)
3 3. Disconnect connector RPE, and connect T-adapter to the female side.
ness
Between ATC3 (female) (3) and RPE (female) (1) Min. 1 MΩ
Resistance
Between ATC3 (female) (18) and RPE (female) (2) Min. 1 MΩ
4
Circuit diagram related to radiator fan pump EPC valve
40-1126 HD465-8, HD605-8


Action level Failure code Radiator Fan Pump EPC Solenoid Ground Fault
Failure
L03 DX16KB (Transmission controller system)
Details of fail- When the controller operates the radiator fan pump EPC valve circuit, too much current flows through the cir-
ure cuit.
q Stops operation of the radiator fan pump EPC valve.
Effect of con-
troller
OFF position.
Effect on the
Radiator fan turns at its maximum speed and fuel consumption may increase.
machine
mation
q Output state of the radiator fan pump EPC valve is seen on monitor function. (Code: 41400 (mA))

2. Disconnect connector RPE, and connect T-adapter to the male side.
1
pump EPC valve Between RPE (male) (1) and (2) 5 to 10 Ω
Resistance
Between ground and RPE (male) (1) or (2) Min. 1 MΩ

2
ing harness Between ATC3 (female) (18) and (3)

Ground fault in wiring har- 3. Disconnect connector RPE, and connect T-adapter to the female side.
3
ness
Between ground and ATC3 (female) (18) or RPE (female)
(1)
Short circuit in wiring har- 2. Disconnect connector RPE, and connect T-adapter to the female side.
4 3. Disconnect connector ATC3, and connect T-adapter to the female side.
ness
Between ATC3 (female) (18) and (3), or between RPE
5
HD465-8, HD605-8 40-1127

40-1128 HD465-8, HD605-8


Action level Failure code Radiator Fan Pump EPC Solenoid Hot Short Circuit
Failure
L01 DX16KY (Transmission controller system)
Details of fail- When the controller does not operate the radiator fan pump EPC valve circuit, current flows through the cir-
ure cuit.
Effect of con-
Stops operation of the radiator fan pump EPC valve.
troller
Effect on the
Radiator may be too hot because of reduced radiator fan speed.
machine
mation q Output state of the radiator fan pump EPC valve is seen on monitor function. (Code: 41400 (mA))

Hot short circuit in wiring 2. Disconnect connector RPE, and connect T-adapter to the female side.
harness
Voltage Between RPE (female) (1) and (2) Max. 4.5 V
2
HD465-8, HD605-8 40-1129


Action level Failure code ABS control valve solenoid (Front Right) Disconnection
Failure
L03 DX21KA (ABS controller system)
Details of fail-
When the controller drives the ABS control valve (front right) circuit, no current flows through the circuit.
ure
Effect of con-
troller
mation Procedure: Turn the starting switch to ON position and enable the ABS setting.

Defective ABS control 2. Disconnect connector ABSFR, and connect T-adapter to male side.
1
valve (front right)
Resistance Between ABSFR (male) (1) and (2) 10 to 30 Ω

Open or short circuit in wir- 2. Disconnect connector OPC3, and connect T-adapter to female side.
2
2. Disconnect connectors OPC3 and ABSFR, and connect T-adapter to each female
3 side.
ness
Between OPC3 (female) (27) and ABSFR (female) (1) Max. 1 Ω
Resistance
Between OPC3 (female) (3) and ABSFR (female) (2) Max. 1 Ω

4 Defective ABS controller ABS setting: OFF Max. 4.5 V

Voltage Between OPC3 (27) and (3)
ABS setting: ON 20 to 30 V
Circuit diagram related to ABS control valve (front right)
40-1130 HD465-8, HD605-8


Action level Failure code ABS control valve solenoid (Front Right) Ground fault
Failure
L03 DX21KB (ABS controller system)
Details of fail- When the controller drives the ABS control valve (front right) circuit, excessive current flows through the cir-
ure cuit.
Effect of con-
troller

2. Disconnect connector ABSFR, and connect T-adapter to male side.
Defective ABS control
1
valve (front right) Between ABSFR (male) (1) and (2) 10 to 30 Ω
Resistance
Between ABSFR (male) (1) and ground Min. 1 MΩ

2

2. Disconnect connectors OPC3 and ABSFR, and connect T-adapter to either female
3
ness
Between ground and OPC3 (female) (27) or ABSFR
(female) (1)
Short circuit in wiring har- 2. Disconnect connectors OPC3 and ABSFR, and connect T-adapter to either female
4 side.
ness
Voltage Min. 1 MΩ
ABSFR (female) (1) and (2)


HD465-8, HD605-8 40-1131

40-1132 HD465-8, HD605-8


Action level Failure code ABS control valve solenoid (Front Right) Hot short
Failure
L03 DX21KY (ABS controller system)
Details of fail-
When the controller does not drive the ABS control valve (front right) circuit, current flows through the circuit.
ure
Effect of con-
troller
mation Procedure: Turn the starting switch to ON position and disable the ABS setting.

Perform the following procedure with the ABS setting disabled.
Hot short circuit in wiring 2. Disconnect connector ABSFR, and connect T-adapter to female side.
1
harness 3. Turn the starting switch to ON position.
Resistance Between ABSFR (female) (1) and (2) Max. 4.5 V


HD465-8, HD605-8 40-1133


Action level Failure code ABS control valve solenoid (Front Right) circuit Abnormality
Failure
L03 DX21MA (ABS controller system)
Details of fail- When the controller drives the ABS control valve (front right) circuit, the oil pressure is not detected, or when
ure the controller does not drive the ABS control valve (front right) circuit, the oil pressure is detected.
Effect of con-
troller
q Check the input signal from the ABS control valve pressure sensor (front right) with monitoring function.
(Code: 43314 (MPa), 43315 (V))
Related infor- q If failure code [DX21KA], [DX21KB], [DX21KY], or [DHU6KX] is displayed, perform troubleshooting for it
mation first.
Procedure: Start the engine and perform the ABS system check.

Defective ABS (front right)
Check and troubleshoot the ABS (front right) hydraulic piping or ABS control valve (front
1 hydraulic circuit or ABS
right).
control valve (front right)
Perform the following procedure with the ABS setting enabled and the front brake cut
function disabled.
2. Connect T-adapter to connector OPC1.
2 valve pressure sensor
(front right)
Between OPC1 (19) and Brake pedal: OFF 0.3 to 0.6 V
Voltage
(21) Brake pedal: ON 0.9 to 4.7 V


40-1134 HD465-8, HD605-8

Circuit diagram related to ABS control valve pressure sensor (front right)
HD465-8, HD605-8 40-1135


Action level Failure code ABS control valve solenoid (Front Left) Disconnection
Failure
Details of fail-
When the controller drives the ABS control valve (front left) circuit, no current flows through the circuit.
ure
Effect of con-
troller

Defective ABS control 2. Disconnect connector ABSFL, and connect T-adapter to male side.
1
valve (front left)
Resistance Between ABSFL (male) (1) and (2) 10 to 30 Ω

2
2. Disconnect connectors OPC3 and ABSFL, and connect T-adapter to each female
3 side.
ness
Between OPC3 (female) (37) and ABSFL (female) (1) Max. 1 Ω
Resistance
Between OPC3 (female) (3) and ABSFL (female) (2) Max. 1 Ω


Circuit diagram related to ABS control valve (front left)
40-1136 HD465-8, HD605-8


Action level Failure code ABS control valve solenoid (Front Left) Ground fault
Failure
Details of fail-
When the controller drives the ABS control valve (front left) circuit, excessive current flows through the circuit.
ure
Effect of con-
troller

2. Disconnect connector ABSFL, and connect T-adapter to male side.
1
valve (front left) solenoid Between ABSFL (male) (1) and (2) 10 to 30 Ω
Resistance
Between ABSFL (male) (1) and ground Min. 1 MΩ

2

2. Disconnect connectors OPC3 and ABSFL, and connect T-adapter to either female
3
ness
Between ground and OPC3 (female) (37) or ABSFL
(female) (1)
Short circuit in wiring har- 2. Disconnect connectors OPC3 and ABSFL, and connect T-adapter to either female
4 side.
ness
Voltage Min. 1 MΩ
ABSFL (female) (1) and (2)


HD465-8, HD605-8 40-1137

40-1138 HD465-8, HD605-8


Action level Failure code ABS control valve solenoid (Front Left) Hot short
Failure
Details of fail-
When the controller does not drive the ABS control valve (front left) circuit, current flows through the circuit.
ure
Effect of con-
troller

Hot short circuit in wiring 2. Disconnect connector ABSFL, and connect T-adapter to female side.
1
Resistance Between ABSFL (female) (1) and (2) Max. 4.5 V


HD465-8, HD605-8 40-1139


Action level Failure code ABS control valve solenoid (Front Left) circuit Abnormality
Failure
Details of fail- When the controller drives the ABS control valve (front left) circuit, the oil pressure is not detected, or when
ure the controller does not drive the ABS control valve (front left) circuit, the oil pressure is detected.
Effect of con-
troller
q Check the input signal from the ABS control valve pressure sensor (front left) with monitoring function.
(Code: 43312 (MPa), 43313 (V))
mation first.

Defective ABS (front left)
Check and troubleshoot the ABS (front left) hydraulic piping or ABS control valve (front
left).
control valve (front left)
Perform the following procedure with the ABS setting enabled and the front brake cut
function disabled.
2. Connect T-adapter to connector OPC1.
2 valve oil pressure sensor
(front left)
Between OPC1 (13) and Brake pedal: OFF 0.3 to 0.6 V
Voltage
(21) Brake pedal: ON 0.9 to 4.7 V


40-1140 HD465-8, HD605-8

Circuit diagram related to ABS control valve pressure sensor (front left)
HD465-8, HD605-8 40-1141


Action level Failure code ABS control valve solenoid (Rear Right) Disconnection
Failure
Details of fail-
When the controller drives the ABS control valve (rear right) circuit, no current flows through the circuit.
ure
Effect of con-
troller

Defective ABS control 2. Disconnect connector ABSRR, and connect T-adapter to male side.
1
valve (rear right) solenoid
Resistance Between ABSRR (male) (1) and (2) 10 to 30 Ω

2
2. Disconnect connectors OPC3 and ABSRR, and connect T-adapter to each female
3 side.
ness
Between OPC3 (female) (6) and ABSRR (female) (1) Max. 1 Ω
Resistance
Between OPC3 (female) (13) and ABSRR (female) (2) Max. 1 Ω


Circuit diagram related to ABS control valve (rear right)
40-1142 HD465-8, HD605-8


Action level Failure code ABS control valve solenoid (Rear Right) Ground fault
Failure
Details of fail- When the controller drives the ABS control valve (rear right) circuit, excessive current flows through the cir-
ure cuit.
Effect of con-
troller

2. Disconnect connector ABSRR, and connect T-adapter to male side.
1
valve (rear right) solenoid Between ABSRR (male) (1) and (2) 10 to 30 Ω
Resistance
Between ABSRR (male) (1) and ground Min. 1 MΩ

2

2. Disconnect connectors OPC3 and ABSRR, and connect T-adapter to either female
3
ness
Between ground and OPC3 (female) (6) or ABSRR
(female) (1)
Short circuit in wiring har- 2. Disconnect connectors OPC3 and ABSRR, and connect T-adapter to either female
4 side.
ness
Voltage Min. 1 MΩ
ABSRR (female) (1) and (2)


HD465-8, HD605-8 40-1143

40-1144 HD465-8, HD605-8


Action level Failure code ABS control valve solenoid (Rear Right) Hot short
Failure
Details of fail-
When the controller does not drive the ABS control valve (rear right) circuit, current flows through the circuit.
ure
Effect of con-
troller

Hot short circuit in wiring 2. Disconnect connector ABSRR, and connect T-adapter to female side.
1
Resistance Between ABSRR (female) (1) and (2) Max. 4.5 V


HD465-8, HD605-8 40-1145


Action level Failure code ABS control valve solenoid (Rear Right) circuit Abnormality
Failure
Details of fail- When the controller drives the ABS control valve (rear right) circuit, the oil pressure is not detected, or when
ure the controller does not drive the ABS control valve (rear right) circuit, the oil pressure is detected.
Effect of con-
troller
q Check the input signal from the ABS control valve pressure sensor (rear right) with monitoring function.
(Code: 43318 (MPa), 43319 (V))
mation first.

Defective ABS (rear right)
Check and troubleshoot the ABS (rear right) hydraulic piping or ABS control valve (rear
right).
control valve (rear right)
Perform the following procedure with the ABS setting enabled.
Defective ABS control 2. Connect T-adapter to connector OPC1.
2 valve oil pressure sensor 3. Start the engine.
(rear right)
Brake pedal: OFF 0.5 to 1.2 V
Brake pedal: ON 1.6 to 4.7 V


40-1146 HD465-8, HD605-8

Circuit diagram related to ABS control valve pressure sensor (rear right)
HD465-8, HD605-8 40-1147


Action level Failure code ABS control valve solenoid (Rear Left) Disconnection
Failure
Details of fail-
When the controller drives the ABS control valve (rear left) circuit, no current flows through the circuit.
ure
Effect of con-
troller

Defective ABS control 2. Disconnect connector ABSRL, and connect T-adapter to male side.
1
valve (rear left) solenoid
Resistance Between ABSRL (male) (1) and (2) 10 to 30 Ω

2
2. Disconnect connectors OPC3 and ABSRL, and connect T-adapter to each female
3 side.
ness
Between OPC3 (female) (16) and ABSRL (female) (1) Max. 1 Ω
Resistance
Between OPC3 (female) (13) and ABSRL (female) (2) Max. 1 Ω

4 Defective ABS controller Between OPC3 (16) and ABS setting: OFF Max. 4.5 V
Voltage
(13) ABS setting: ON 20 to 30 V
Circuit diagram related to ABS control valve (rear left)
40-1148 HD465-8, HD605-8


Action level Failure code ABS control valve solenoid (Rear Left) Ground fault
Failure
Details of fail-
When the controller drives the ABS control valve (rear left) circuit, excessive current flows through the circuit.
ure
Effect of con-
troller

2. Disconnect connector ABSRL, and connect T-adapter to male side.
1
valve (rear left) solenoid Between ABSRL (male) (1) and (2) 10 to 30 Ω
Resistance
Between ABSRL (male) (1) and ground Min. 1 MΩ

2

2. Disconnect connectors OPC3 and ABSRL, and connect T-adapter to either female
3
ness
Between ground and OPC3 (female) (16) or ABSRL
(female) (1)
Short circuit in wiring har- 2. Disconnect connectors OPC3 and ABSRL, and connect T-adapter to either female
4 side.
ness
Voltage Min. 1 MΩ
ABSRL (female) (1) and (2)


HD465-8, HD605-8 40-1149

40-1150 HD465-8, HD605-8


Action level Failure code ABS control valve solenoid (Rear Left) Hot short
Failure
Details of fail-
When the controller does not drive the ABS control valve (rear left) circuit, current flows through the circuit.
ure
Effect of con-
troller

Hot short circuit in wiring 2. Disconnect connector ABSRL, and connect T-adapter to female side.
1
Resistance Between ABSRL (female) (1) and (2) Max. 4.5 V

Voltage
HD465-8, HD605-8 40-1151


Action level Failure code ABS control valve solenoid (Rear Left) circuit Abnormality
Failure
Details of fail- When the controller drives the ABS control valve (rear left) circuit, the oil pressure is not detected, or when
ure the controller does not drive the ABS control valve (rear left) circuit, the oil pressure is detected.
Effect of con-
troller
q Check the input signal from the ABS control valve pressure sensor (rear left) with monitoring function.
(Code: 43316 (MPa), 43317 (V))
mation first.

Defective ABS (rear left)
Check and troubleshoot the ABS (rear left) hydraulic piping or ABS control valve (rear
left).
control valve (rear left)
Perform the following procedure with the ABS setting enabled.
Defective ABS control 2. Connect T-adapter to connector OPC1.
2 valve oil pressure sensor 3. Start the engine.
(rear left)
Brake pedal: OFF 0.5 to 1.2 V
Brake pedal: ON 1.6 to 4.7 V

Voltage
40-1152 HD465-8, HD605-8

Circuit diagram related to ABS control valve pressure sensor (rear left)
HD465-8, HD605-8 40-1153


Action level Failure code ABS control valve solenoid (Front) circuit Abnormality
Failure
Details of fail- Responses from the ABS control valve pressure sensor (front right, front left) do not match the command to
ure the ABS control valve (rear).
Effect of con-
troller

q Check and troubleshoot the ABS (front) hydraulic piping or ABS control valve (front
Defective ABS (front)
right, front left).
hydraulic circuit or ABS
1 q Perform the ABS system check to make sure that failure code [DX21MA] or [DX22MA]
control valve (front right,
is displayed.
front left)
Perform troubleshooting for the displayed failure code.
40-1154 HD465-8, HD605-8


Action level Failure code ABS control valve solenoid (Rear) circuit Abnormality
Failure
Details of fail- Responses from the ABS control valve pressure sensor (rear right, rear left) do not match the command to
ure the ABS control valve (rear).
Effect of con-
troller

q Check and troubleshoot the ABS (rear) hydraulic piping or ABS control valve (rear
Defective ABS (rear)
right, rear left).
hydraulic circuit or ABS
1 q Perform the ABS system check to make sure that failure code [DX23MA] or [DX24MA]
control valve (rear right,
is displayed.
rear left)
Perform troubleshooting for the displayed failure code.
HD465-8, HD605-8 40-1155


Action level Failure code KTCS EPC Solenoid Release Trouble (Rear Right)
Failure
Details of fail- KTCS EPC oil pressure is sensed when the controller does not operate the KTCS EPC valve solenoid (rear
ure right) circuit.
Effect of con-
troller
OFF position.
Effect on the
KTCS does not work.
machine
q Examine the signal from the KTCS oil pressure sensor (rear) with monitor function. (Code: 49006 (MPa),

q Examine and troubleshoot the KTCS (rear right) hydraulic piping, KTCS EPC valve
Defective KTCS (rear right)
(rear right) or KTCS shut-off valve.
1 hydraulic circuit or KTCS
q To troubleshoot refer to TEST AND ADJUST, "PROCEDURE TO TEST PARKING
EPC valve (rear right)
BRAKE OIL PRESSURE".

2. Connect T-adapter to connector BRC1.
REMARK
For details of KTCS valve setting mode, see "PROCEDURE TO ADJUST WITH ADJUST-
0.30 to 0.59
KTCS: OFF
V
Voltage Between BRC1 (13) and (4) KTCS: ON
1.09 to 1.26
(ON in KTCS Valve setting
V
mode)

KTCS: OFF Max. 4.5 V
hoist controller Voltage KTCS: ON
(23) (ON in KTCS Valve setting 20 to 30 V
mode)
40-1156 HD465-8, HD605-8

Circuit diagram related to KTCS EPC valve (rear right)
HD465-8, HD605-8 40-1157


Action level Failure code KTCS EPC Solenoid Output Open Circuit (Rear Right)
Failure
Details of fail-
When the controller operates the KTCS EPC valve (rear right) circuit, no current flows through the circuit.
ure
Effect of con-
troller
OFF position.
Effect on the
KTCS does not work.
machine
Related infor-
mation

Defective KTCS EPC valve 2. Disconnect connector TCS3, and connect T-adapter to the male side.
1
(rear right)
Resistance Between TCS3 (male) (1) and (2) 10 to 30 Ω

2
Open circuit in wiring har- 2. Disconnect connectors BRC3 and TCS3, and connect T-adapter to each female side.
3
ness
Resistance

REMARK
Defective retarder and MENT MENU (KTCS VALVE SETTING)".
4
hoist controller KTCS: OFF Max. 4.5 V
Between BRC3 (16) and KTCS: ON
Voltage
mode)
40-1158 HD465-8, HD605-8

HD465-8, HD605-8 40-1159


Action level Failure code KTCS EPC Solenoid Output Ground Fault (Rear Right)
Failure
Details of fail- When the controller operates the KTCS EPC valve (rear right) circuit, too much current flows through the cir-
ure cuit.
Effect of con-
troller
OFF position.
Effect on the
KTCS does not work.
machine
mation Procedure: Start the engine and actuate the KTCS in the KTCS Valve setting mode.

Defective KTCS EPC valve
1
(rear right) Between TCS3 (male) (1) and (2) 10 to 30 Ω
Resistance

2

Ground fault in wiring har- 2. Disconnect connectors BRC3 and TCS3, and connect T-adapter to the female side of
3 TCS3.
ness
Resistance Between TCS3 (female) (1) and ground Min. 1 MΩ
Short circuit in wiring har- 2. Disconnect connectors BRC3 and TCS3, and connect T-adapter to either female side.
4
ness
Between BRC3 (female) (16) and (23), or between TCS3

REMARK
5
Voltage
mode)
40-1160 HD465-8, HD605-8

HD465-8, HD605-8 40-1161

FAILURE CODE [DX37KY] 40 TROUBLESHOOTING

Action level Failure code KTCS EPC Solenoid Output Hot Short Circuit (Rear Right)
Failure
Details of fail- When the controller does not operate the KTCS EPC valve (rear right) circuit, current flows through the cir-
ure cuit.
Effect of con-
troller
Effect on the
KTCS does not work.
machine

Hot short circuit in wiring 2. Disconnect connector TSC3, and connect T-adapter to the female side.
harness
Voltage Between TSC3 (female) (1) and (2) Max. 4.5 V

REMARK
2
Voltage
mode)
40-1162 HD465-8, HD605-8


Action level Failure code KTCS EPC Solenoid Malfunction (Rear Right)
Failure
Details of fail-
KTCS EPC oil pressure is not sensed when the controller operates the KTCS EPC valve (rear right) circuit.
ure
Effect of con-
troller
OFF position.
Effect on the
KTCS does not work.
machine
q Examine the signal from the KTCS oil pressure sensor (rear right) with monitor function (Code: 49006
Procedure: Start the engine and actuate the KTCS in the KTCS Valve setting mode.

q Examine and troubleshoot the KTCS (rear right) hydraulic piping, KTC EPC valve
Defective KTCS (rear right)
(rear right) or KTCS shut-off valve.
EPC valve (rear right)

2. Connect T-adapter to connector BRC1.
REMARK
0.30 to 0.59
KTCS: OFF
V
1.09 to 1.26
(ON in KTCS Valve Fixing
V
mode)

hoist controller Voltage KTCS: ON
mode)
HD465-8, HD605-8 40-1163

40-1164 HD465-8, HD605-8


Action level Failure code KTCS EPC Valve Release Trouble (Rear Left)
Failure
Details of fail-
KTCS EPC oil pressure is sensed when the controller does not operate the KTCS EPC valve (rear left) circuit.
ure
Effect of con-
troller
OFF position.
Effect on the
KTCS does not work.
machine
q Examine the signal from the KTCS oil pressure sensor (rear left) with monitor function. (Code: 49004

q Inspect and troubleshoot the KTCS (rear left) hydraulic piping, KTCS EPC valve (rear
Defective KTCS (rear left)
left) or KTCS shut-off valve.
EPC valve (rear left)

2. Connect T-adapter to connectors BRC1 and BRC2.
REMARK
0.30 to 0.59
KTCS: OFF
V
Voltage KTCS: ON
BRC1 (4) 1.09 to 1.26
V
mode)

3
hoist controller Voltage Between BRC3 (6) and (23) KTCS: ON
(ON in KTCS Valve setting 20 to 30 V
mode)
HD465-8, HD605-8 40-1165

Circuit diagram related to KTCS EPC valve (rear left)
40-1166 HD465-8, HD605-8


Action level Failure code KTCS EPC Solenoid Output Open Circuit (Rear Left)
Failure
Details of fail-
When the controller operates the KTCS EPC valve (rear left) circuit, no current flows through the circuit.
ure
Effect of con-
troller
OFF position.
Effect on the
KTCS does not work.
machine

Defective KTCS EPC valve 2. Disconnect connector TSC4, and connect T-adapter to the male side.
1
(rear left)
Resistance Between TSC4 (male) (1) and (2) 10 to 30 Ω

2
Open circuit in wiring har- 2. Disconnect connectors BRC3 and TCS4, and connect T-adapter to each female side.
3
ness
Between BRC3 (female) (6) and TSC4 (female) (1) Max. 1 Ω
Resistance
Between BRC3 (female) (23) and TSC4 (female) (2) Max. 1 Ω

REMARK
4

mode)
HD465-8, HD605-8 40-1167

40-1168 HD465-8, HD605-8


Action level Failure code KTCS EPC Solenoid Output Ground Fault (Rear Left)
Failure
Details of fail-
When the controller operates the KTCS EPC valve rear left) circuit, too much current flows through the circuit.
ure
Effect of con-
troller
OFF position.
Effect on the
KTCS does not work.
machine

Defective KTCS EPC valve
1
(rear left) Between TCS4 (male) (1) and (2) 10 to 30 Ω
Resistance

2

Ground fault in wiring har- 2. Disconnect connectors BRC3 and TCS4, and connect T-adapter to the female side of
3 TCS4.
ness
Resistance Between TCS4 (female) (1) and ground Min. 1 MΩ
Short circuit in wiring har- 2. Disconnect connectors BRC3 and TCS4, and connect T-adapter to either female side.
4
ness
Between BRC3 (female) (6) and (23), or between TCS4
Value Min. 1 MΩ

REMARK
5

mode)
HD465-8, HD605-8 40-1169

40-1170 HD465-8, HD605-8


Action level Failure code KTCS EPC Solenoid Output Hot Short Circuit (Rear Left)
Failure
Details of fail-
When the controller does not operate the KTCS EPC valve (rear left) circuit, current flows through the circuit.
ure
Effect of con-
troller
Effect on the
KTCS does not work.
machine

Hot short circuit in wiring 2. Disconnect connector TSC4, and connect T-adapter to the female side.
harness
Voltage Between TSC4 (female) (1) and (2) Max. 4.5 V

REMARK
2

mode)
HD465-8, HD605-8 40-1171


Action level Failure code KTCS EPC Valve Malfunction (Rear Left)
Failure
Details of fail-
KTCS EPC oil pressure is not sensed when the controller operates the KTCS EPC valve (rear left) circuit.
ure
Effect of con-
troller
OFF position.
Effect on the
KTCS does not work.
machine
q Examine the signal from the KTCS oil pressure sensor (rear left) with monitor function. (Code: 49004
Procedure: Start the engine and actuate the KTCS in the KTCS Valve setting mode.

q Inspect and troubleshoot the KTCS (rear left) hydraulic piping, KTCS EPC valve (rear
Defective KTCS (rear left)
left) or KTCS shut-off valve.
EPC valve (rear left)

2. Connect T-adapter to connectors BRC1 and BRC2.
REMARK
0.30 to 0.59
KTCS: OFF
V
Voltage KTCS: ON
BRC1 (4) 1.09 to 1.26
V
mode)

3
hoist controller Voltage Between BRC3 (6) and (23) KTCS: ON
mode)
40-1172 HD465-8, HD605-8

HD465-8, HD605-8 40-1173

FAILURE CODE [DXH1KA] 40 TROUBLESHOOTING
FAILURE CODE [DXH1KA]

Action level Failure code ECMV Solenoid Open Circuit (Lock Up Clutch)
Failure
L03 DXH1KA (Transmission controller system)
Details of fail-
When the controller operates lockup clutch ECMV, no current flows through the circuit.
ure
Effect of con-
troller
OFF position.

mation q Output current to lockup clutch ECMV is seen on monitor function. (Code: 31609 (mA))
Procedure: Turn the start switch to the ON position and wait for 5 seconds. ( 5 seconds after start switch
is turned to ON position, the controller operates solenoid and performs self-check).

2. Disconnect connector L/U,PS, and connect T-adapter to the male side.
Defective lockup clutch
1
ECMV Between L/U,PS (male) (1) and (2) 5 to 15 Ω
Resistance
Between ground and L/U,PS (male) (1) or (2) Min. 1 MΩ

Open or short circuit in wir- If the check result is unusual, disconnect connector J09 and troubleshoot to locate defec-
2
ing harness tive wiring harness.
Resistance Between ATC3 (female) (15) and (23) 5 to 15 Ω
3 3. Disconnect connector L/U,PS, and connect T-adapter to the female side.
ness
Between ATC3 (female) (15) and L/U,PS (female) (1) Max. 1 Ω
Resistance
Between ATC3 (female) (23) and L/U,PS (female) (2) Max. 1 Ω
4
40-1174 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DXH1KA]
Circuit diagram related to lockup clutch
HD465-8, HD605-8 40-1175

FAILURE CODE [DXH1KB] 40 TROUBLESHOOTING
FAILURE CODE [DXH1KB]

Action level Failure code ECMV Solenoid Ground Fault (Lock Up Clutch)
Failure
L03 DXH1KB (Transmission controller system)
Details of fail-
When the controller operates lockup clutch ECMV, too much current flows through the circuit.
ure
Effect of con-
troller
OFF position.


2. Disconnect connector L/U,PS, and connect T-adapter to the male side.
Defective lockup clutch
1
ECMV Between L/U,PS (male) (1) and (2) 5 to 15 Ω
Resistance
Between ground and L/U,PS (male) (1) or (2) Min. 1 MΩ

2

Ground fault in wiring har- 3. Disconnect connector L/U,PS, and connect T-adapter to the female side.
3
ness
Between ground and ATC3 (female) (15) or L/U,PS
(female) (1)
4 3. Disconnect connector L/U,PS, and connect T-adapter to the female side.
ness
Between ATC3 (female) (15) and (23), or between L/U,PS
5
40-1176 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DXH1KB]
HD465-8, HD605-8 40-1177

FAILURE CODE [DXH1KY] 40 TROUBLESHOOTING
FAILURE CODE [DXH1KY]

Action level Failure code ECMV Solenoid Hot Short Circuit (Lock Up Clutch)
Failure
L03 DXH1KY (Transmission controller system)
Details of fail-
When the controller does not operate lockup clutch ECMV, current flows through the circuit.
ure
Effect of con-
troller
OFF position.
q Lockup clutch remains engaged.
Effect on the
machine
q After the machine stops, it can move forward when the gear speed is set to F2 by setting the gear shift

Hot short circuit in wiring 2. Disconnect connector L/U,PS, and connect T-adapter to the female side.
harness
Voltage Between L/U,PS (female) (1) and (2) Max. 4.5 V

2. Disconnect connector L/U,PS.
2
ness
(15)
3
40-1178 HD465-8, HD605-8


Action level Failure code ECMV Solenoid Open Circuit (High)
Failure
Details of fail-
When the controller operates H clutch ECMV, no current flows through the circuit.
ure
q Shifts up gear relative to gear speed when a failure is found as shown in Table 1 and holds that gear
speed.
Effect of con-
troller
OFF position.
q Machine travels in gear speed that does not use the H clutch.

mation q Output current to H clutch ECMV is seen on monitor function. (Code: 31600 (mA))

2. Disconnect connector H,PS, and connect T-adapter to the male side.
1 Defective H clutch ECMV
Between H,PS (male) (1) and (2) 5 to 15 Ω
Resistance
Between ground and H,PS (male) (1) or (2) Min. 1 MΩ

2
ing harness
3 3. Disconnect connector H,PS, and connect T-adapter to the female side.
ness
Between ATC3 (female) (6) and H,PS (female) (1) Max. 1 Ω
Resistance
Between ATC3 (female) (3) and H,PS (female) (2) Max. 1 Ω
4
HD465-8, HD605-8 40-1179

Table 1
Remedy when failure is found

Gear speed when failure is
Incorrect clutch Effect of controller ON/OFF state of
sensed
(Selected clutch, gear speed) lockup clutch

F7

F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF

F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF

F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF

F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF

F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF

F1
Low Low 2H F3 OFF

40-1180 HD465-8, HD605-8


Action level Failure code ECMV Solenoid Ground Fault (High)
Failure
Details of fail-
When the controller operates H clutch ECMV, too much current flows through the circuit.
ure
speed.
Effect of con-
troller
OFF position.
q Machine travels in gear speed that does not use the H clutch.

mation q Output current to H clutch ECMV is seen on monitor function. (Code: 31600 (mA))

2. Disconnect connector H,PS, and connect T-adapter to the male side.
1 Defective H clutch ECMV
Between H,PS (male) (1) and (2) 5 to 15 Ω
Resistance
Between ground and H,PS (male) (1) or (2) Min. 1 MΩ

2
ing harness

Ground fault in wiring har- 3. Disconnect connector H,PS, and connect T-adapter to the female side.
3
ness
Between ground and ATC3 (female) (6) or H,PS (female)
(1)
4 3. Disconnect connector H,PS, and connect T-adapter to the female side.
ness
Between ATC3 (female) (6) and (3), or between H,PS
5
HD465-8, HD605-8 40-1181

Table 1

sensed

F7

F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF

F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF

F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF

F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF

F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF

F1
Low Low 2H F3 OFF

40-1182 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DXH2KY]

Action level Failure code ECMV Solenoid Hot Short Circuit (High)
Failure
Details of fail-
When the controller does not operate the H clutch ECMV solenoid, current flows through the circuit.
ure
speed.
Effect of con-
troller
OFF position.
q Machine travels in gear speed that uses H clutch.
mation
q Output current to H clutch ECMV is seen on monitor function. (Code: 31600 (mA))

Hot short circuit in wiring 2. Disconnect connector H,PS, and connect T-adapter to the female side.
harness
Voltage Between H,PS (female) (1) and (2) Max. 4.5 V

Short circuit in wiring har- 2. Disconnect connector H,PS.
ness
3
HD465-8, HD605-8 40-1183

Table 2

sensed
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
40-1184 HD465-8, HD605-8


sensed
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH R OFF
HD465-8, HD605-8 40-1185


Action level Failure code ECMV Solenoid Open Circuit (Low)
Failure
Details of fail-
When the controller operates L clutch ECMV, no current flows through the circuit.
ure
speed.
Effect of con-
troller
OFF position.
q Machine travels in gear speed that does not use the L clutch.
Phenomenon not shift. The machine must stop before the gear will shift.
on machine q After the machine stops, it can move forward when the gear speed is set to F2 by setting the gear shift

mation q Output current to L clutch ECMV is seen on monitor function. (Code: 31601 (mA))

2. Disconnect connector L,PS, and connect T-adapter to the male side.
1 Defective L clutch ECMV
Between L,PS (male) (1) and (2) 5 to 15 Ω
Resistance
Between ground and L,PS (male) (1) or (2) Min. 1 MΩ

2
ing harness
3 3. Disconnect connector L,PS, and connect T-adapter to the female side.
ness
Between ATC3 (female) (27) and L,PS (female) (1) Max. 1 Ω
Resistance
Between ATC3 (female) (13) and L,PS (female) (2) Max. 1 Ω
4
40-1186 HD465-8, HD605-8

Table 1

sensed

F7

F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF

F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF

F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF

F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF

F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF

F1
Low Low 2H F3 OFF

HD465-8, HD605-8 40-1187


Action level Failure code ECMV Solenoid Ground Fault (Low)
Failure
Details of fail-
When the controller operates L clutch ECMV, too much current flows through the circuit.
ure
speed.
Effect of con-
troller
OFF position.
q Machine travels in gear speed that does not use the L clutch.

mation q Output current to L clutch ECMV is seen on monitor function. (Code: 31601 (mA))

2. Disconnect connector L,PS, and connect T-adapter to the male side.
1 Defective L clutch ECMV
Between L,PS (male) (1) and (2) 5 to 15 Ω
Resistance
Between ground and L,PS (male) (1) or (2) Min. 1 MΩ

2
ing harness

Ground fault in wiring har- 3. Disconnect connector L,PS, and connect T-adapter to the female side.
3
ness
Between ground and ATC3 (female) (27) or L,PS (female)
(1)
4 3. Disconnect connector L,PS, and connect T-adapter to the female side.
ness
Between ATC3 (female) (27) and (13), or between L,PS
5
40-1188 HD465-8, HD605-8

Table 1

sensed

F7

F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF

F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF

F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF

F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF

F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF

F1
Low Low 2H F3 OFF

HD465-8, HD605-8 40-1189


Action level Failure code ECMV Solenoid Hot Short Circuit (Low)
Failure
Details of fail-
When the controller does not operate the L clutch ECMV solenoid, current flows through the circuit.
ure
speed.
Effect of con-
troller
OFF position.
q Machine travels in gear speed that uses L clutch.
mation
q Output current to L clutch ECMV is seen on monitor function. (Code: 31601 (mA))

Hot short circuit in wiring 2. Disconnect connector L,PS, and connect T-adapter to the female side.
harness
Voltage Between L,PS (female) (1) and (2) Max. 4.5 V

2. Disconnect connector L,PS.
2
ness
(27)
3
40-1190 HD465-8, HD605-8

Table 2

sensed
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
HD465-8, HD605-8 40-1191


sensed
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH R OFF
40-1192 HD465-8, HD605-8


Action level Failure code ECMV Solenoid Open Circuit (1st)
Failure
Details of fail-
When the controller operates 1st clutch ECMV, no current flows through the circuit.
ure
speed.
Effect of con-
troller
OFF position.
q Machine travels in gear speed that does not use the 1st clutch.

mation q Output current to 1st clutch ECMV is seen on monitor function. (Code: 31602 (mA))

2. Disconnect connector 1,PS, and connect T-adapter to the male side.
1 Defective 1st clutch ECMV
Between 1,PS (male) (1) and (2) 5 to 15 Ω
Resistance
Between ground and 1,PS (male) (1) or (2) Min. 1 MΩ

2
ing harness
3 3. Disconnect connector 1,PS, and connect T-adapter to the female side.
ness
Between ATC3 (female) (16) and 1,PS (female) (1) Max. 1 Ω
Resistance
4
HD465-8, HD605-8 40-1193

Table 1

sensed

F7

F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF

F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF

F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF

F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF

F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF

F1
Low Low 2H F3 OFF

40-1194 HD465-8, HD605-8


Action level Failure code ECMV Solenoid Ground Fault (1st)
Failure
Details of fail-
When the controller operates 1st clutch ECMV, too much current flows through the circuit.
ure
speed.
Effect of con-
troller
OFF position.
q Machine travels in gear speed that does not use the 1st clutch.

mation q Output current to 1st clutch ECMV is seen on monitor function. (Code: 31602 (mA))

1 Defective 1st clutch ECMV
Resistance

2
ing harness

Ground fault in wiring har- 3. Disconnect connector 1,PS, and connect T-adapter to the female side.
3
ness
Between ground and ATC3 (female) (16) or 1,PS (female)
(1)
ness
Between ATC3 (female) (16) and (3), or between 1,PS
5
HD465-8, HD605-8 40-1195

Table 1

sensed

F7

F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF

F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF

F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF

F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF

F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF

F1
Low Low 2H F3 OFF

40-1196 HD465-8, HD605-8


Action level Failure code ECMV Solenoid Hot Short Circuit (1st)
Failure
Details of fail-
When the controller does not operate the 1st clutch ECMV solenoid, current flows through the circuit.
ure
speed.
Effect of con-
troller
OFF position.
q Machine travels in gear speed that uses the 1st clutch.
lever to a position between D and L,. The machine can move rearward when the gear speed is set to R
mation
q Output current to 1st clutch ECMV is seen on monitor function. (Code: 31602 (mA))

Hot short circuit in wiring 2. Disconnect connector 1,PS, and connect T-adapter to the female side.
harness
Voltage Between 1,PS (female) (1) and (2) Max. 4.5 V

2. Disconnect connector 1,PS.
2
ness
(16)
3
HD465-8, HD605-8 40-1197

Table 2

sensed
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
40-1198 HD465-8, HD605-8


sensed
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH R OFF
HD465-8, HD605-8 40-1199


Action level Failure code ECMV Solenoid Open Circuit (2nd)
Failure
Details of fail-
When the controller operates 2nd clutch ECMV, no current flows through the circuit.
ure
speed.
Effect of con-
troller
OFF position.
q Machine travels in gear speed that does not use the 2nd clutch.

mation q Output current to 2nd clutch ECMV is seen on monitor function. (Code: 31603 (mA))

1
ECMV Between 2,PS (male) (1) and (2) 5 to 15 Ω
Resistance

2
ness
Resistance
4
40-1200 HD465-8, HD605-8

Table 1

sensed

F7

F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF

F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF

F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF

F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF

F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF

F1
Low Low 2H F3 OFF

HD465-8, HD605-8 40-1201


Action level Failure code ECMV Solenoid Ground Fault (2nd)
Failure
Details of fail-
When the controller operates 2nd clutch ECMV, too much current flows through the circuit.
ure
speed.
Effect of con-
troller
OFF position.
q Machine travels in gear speed that does not use the 2nd clutch.
Related infor- hoist lever to the "HOLD" position and set the lock knob to the LOCK position. Make sure to en-
Output current to 2nd clutch ECMV is seen on monitor function. (Code: 31603 (mA))

1
ECMV Between 2,PS (male) (1) and (2) 5 to 15 Ω
Resistance

2

3
ness
(1)
ness
5
40-1202 HD465-8, HD605-8

Table 1

sensed

F7

F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF

F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF

F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF

F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF

F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF

F1
Low Low 2H F3 OFF

HD465-8, HD605-8 40-1203


Action level Failure code ECMV Solenoid Hot Short Circuit (2nd)
Failure
Details of fail-
When the controller does not operate 2nd clutch ECMV solenoid, current flows through the circuit.
ure
speed.
Effect of con-
troller
OFF position.
q Machine travels in gear speed that uses the 2nd clutch.
Effect on the
machine
lever to a position between D and L. But the machine cannot move rearward.
mation q Output current to 2nd clutch ECMV is seen on monitor function. (Code: 31603 (mA))

harness
Voltage Between 2,PS (female) (1) and (2) Max. 4.5 V

2
ness
(26)
3
40-1204 HD465-8, HD605-8

Table 2

sensed
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
HD465-8, HD605-8 40-1205


sensed
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH R OFF
40-1206 HD465-8, HD605-8


Action level Failure code ECMV Solenoid Open Circuit (3rd)
Failure
Details of fail-
When the controller operates 3rd clutch ECMV, no current flows through the circuit.
ure
speed.
Effect of con-
troller
OFF position.
q Machine travels in gear speed that does not use the 3rd clutch.

mation q Output current to 3rd clutch ECMV is seen on monitor function. (Code: 31604 (mA))

1 Defective 3rd clutch ECMV
Resistance

2
ness
Resistance
4
HD465-8, HD605-8 40-1207

Table 1

sensed

F7

F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF

F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF

F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF

F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF

F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF

F1
Low Low 2H F3 OFF

40-1208 HD465-8, HD605-8


Action level Failure code ECMV Solenoid Ground Fault (3rd)
Failure
Details of fail-
When the controller operates 3rd clutch ECMV, too much current flows through the circuit.
ure
speed.
Effect of con-
troller
OFF position.
q Machine travels in gear speed that does not use the 3rd clutch.


1 Defective 3rd clutch ECMV
Resistance

2

3
ness
(1)
ness
5
HD465-8, HD605-8 40-1209

Table 1

sensed

F7

F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF

F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF

F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF

F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF

F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF

F1
Low Low 2H F3 OFF

40-1210 HD465-8, HD605-8


Action level Failure code ECMV Solenoid Hot Short Circuit (3rd)
Failure
Details of fail-
When the controller does not operate the 3rd clutch ECMV, current flows through the circuit.
ure
speed.
Effect of con-
troller
OFF position.
q Machine travels in gear speed that uses the 3rd clutch.
Effect on the
machine
q After the machine stops, the gear speed is set to F4 by setting the gear shift lever to a position between
D and L. The machine cannot move rearward.

harness
Resistance Between 3,PS (female) (1) and (2) Max. 4.5 V

2
ness
(36)
3
HD465-8, HD605-8 40-1211

Table 2

sensed
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
40-1212 HD465-8, HD605-8


sensed
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH R OFF
HD465-8, HD605-8 40-1213


Action level Failure code ECMV Solenoid Open Circuit (Reverse)
Failure
Details of fail-
When the controller operates R clutch ECMV, no current flows through the circuit.
ure
Effect of con- q Disengages lockup clutch.
OFF position.
q Gear shift cannot occur until the machine is stopped.
Effect on the
machine

mation q Output current to R clutch ECMV is seen on monitoring function. (Code: 31606 (mA))

2. Disconnect connector R,PS, and connect T-adapter to the male side.
1 Defective R clutch ECMV
Between R,PS (male) (1) and (2) 5 to 15 Ω
Resistance
Between ground and R,PS (male) (1) or (2) Min. 1 MΩ

2
ing harness
3 3. Disconnect connector R,PS, and connect T-adapter to the female side.
ness
Between ATC3 (female) (5) and R,PS (female) (1) Max. 1 Ω
Resistance
Between ATC3 (female) (23) and R,PS (female) (2) Max. 1 Ω
4
40-1214 HD465-8, HD605-8

HD465-8, HD605-8 40-1215


Action level Failure code ECMV Solenoid Ground Fault (Reverse)
Failure
Details of fail-
When the controller operates R clutch ECMV, too much current flows through the circuit.
ure
OFF position.
Effect on the
machine


2. Disconnect connector R,PS, and connect T-adapter to the male side.
1 Defective R clutch ECMV
Between R,PS (male) (1) and (2) 5 to 15 Ω
Resistance
Between ground and R,PS (male) (1) or (2) Min. 1 MΩ

2
ing harness

Ground fault in wiring har- 3. Disconnect connector R,PS, and connect T-adapter to the female side.
3
ness
Between ground and ATC3 (female) (5) or R,PS (female)
(1)
4 3. Disconnect connector R,PS, and connect T-adapter to the female side.
ness
Between ATC3 (female) (5) and (23), or between R,PS
5
40-1216 HD465-8, HD605-8

HD465-8, HD605-8 40-1217


Action level Failure code ECMV Solenoid Hot Short Circuit (Reverse)
Failure
Details of fail-
When the controller does not operate R clutch ECMV, current flows through the circuit.
ure
OFF position.
Effect on the
q After the machine stops, it moves rearward but not forward when the gear speed is set to R by setting the
machine
gear shift lever to R position.

Hot short circuit in wiring 2. Disconnect connector R,PS, and connect T-adapter to the female side.
harness
Voltage Between R,PS (female) (1) and ground Max. 4.5 V

Short circuit in wiring har- 2. Disconnect connector R,PS.
ness
3
40-1218 HD465-8, HD605-8

HD465-8, HD605-8 40-1219

FAILURE CODE [DXHHKA] 40 TROUBLESHOOTING
FAILURE CODE [DXHHKA]

Action level Failure code Clutch Solenoid Output Open Circuit (4th)
Failure
L03 DXHHKA (Transmission controller system)
Details of fail-
When the controller operates 4th clutch ECMV, no current flows through the circuit.
ure
OFF position.
q Gear speed is held in NEUTRAL and gear shift does not occur until the machine is stopped.
Effect on the q After the machine stops, it can move forward when the gear speed is set to F2 by setting the gear shift
machine lever to a position between D and L. The machine can move backward when the gear speed is set to R

mation q Output current to 4th clutch ECMV is seen on monitor function. (Code: 31605)
Procedure: Turn the start switch to ON position and wait for 5 seconds. (5 seconds after the start switch
is turned to the ON position, controller operates solenoid and performs self-check).

1 Defective 4th clutch ECMV 2. Disconnect connector 4,PS, and connect T-adapter to the male side.
Resistance Between 4,PS (male) (1) and (2) 5 to 15 Ω

2
ing harness
ness
Resistance
4
40-1220 HD465-8, HD605-8

40 TROUBLESHOOTING FAILURE CODE [DXHHKA]
Circuit diagram related to 4th clutch ECMV
HD465-8, HD605-8 40-1221

FAILURE CODE [DXHHKB] 40 TROUBLESHOOTING
FAILURE CODE [DXHHKB]

Action level Failure code Clutch Solenoid Output Ground Fault (4th)
Failure
L03 DXHHKB (Transmission controller system)
Details of fail-
When the controller operates 4th clutch ECMV, too much current flows through the circuit.
ure
q

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Available Formats

SEN06605-11

DUMP TRUCK HD465 -8

HD465-8, HD605-8 00-1

00-2 HD465-8, HD605-8

RADIATOR FAN CONTROL SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-48

HD465-8, HD605-8 00-3

FUNCTION OF WORK EQUIPMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-306

00-4 HD465-8, HD605-8

TEST STEERING CYLINDER PRESSURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-104

HD465-8, HD605-8 00-5

TROUBLESHOOTING POINTS FOR AFTERTREATMENT SYSTEMS- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-22

00-6 HD465-8, HD605-8

FAILURE CODE [2G42ZG] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-243

HD465-8, HD605-8 00-7

FAILURE CODE [CA227] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-318

00-8 HD465-8, HD605-8

FAILURE CODE [CA1844]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-420

HD465-8, HD605-8 00-9

FAILURE CODE [CA3311] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-527

00-10 HD465-8, HD605-8

FAILURE CODE [CB1922]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-625

HD465-8, HD605-8 00-11

FAILURE CODE [D19HKZ] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-723

00-12 HD465-8, HD605-8

FAILURE CODE [DB2QKR] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-808

HD465-8, HD605-8 00-13

FAILURE CODE [DHA4KA]- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-922

00-14 HD465-8, HD605-8

FAILURE CODE [DLF2LC] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1017

HD465-8, HD605-8 00-15

FAILURE CODE [DWD7K4] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1096

00-16 HD465-8, HD605-8

FAILURE CODE [DXH1KB] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1176

HD465-8, HD605-8 00-17

E-18 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY- - - - - - - - - - - - - - - - - - - - - - - - - - 40-1283

00-18 HD465-8, HD605-8

TROUBLESHOOTING OF ENGINE (S-MODE)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-1379

HD465-8, HD605-8 00-19

DISASSEMBLE AND ASSEMBLE OF OUTPUT SHAFT ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-335

00-20 HD465-8, HD605-8

REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-629

HD465-8, HD605-8 00-21

PRECAUTIONS FOR REFRIGERANT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-9

00-22 HD465-8, HD605-8

HD465-8, HD605-8 00-23

List of abbreviations used in the text

Function (major applicable

Automatic Idle Setting

Steering A lever is used to perform the steering operations. It

A device attached onto the standard machine, to let

Brake When the retarder is not used, this valve bypasses

Communication and One of the communication standards that is used in

Crankcase Depression A valve installed in the KCCV. It is written as CDR

This system can actuate several actuators at the

Engine controller electronically controls supply

Electronic control device which uses the signals

00-24 HD465-8, HD605-8

Function (major applicable

Transmission Electromagnetic valve that gradually proportions oil