Komatsu HD465-7E0, HD605-7E0 Dump Truck Service Manual
1,699 pages · Publication SEN01081-19
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What's inside
From the manual's own table of contents: 248 sections, 549 entries. See sample pages (PDF, 836 KB)
Composition of shop manual
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table
Specification drawing
Specifications
Weight table
Fuel, coolant and lubricants
Radiator, torque converter oil cooler, after cooler, work equipment oil cooler, fuel cooler
Fuel system
Brake oil cooler
Output shaft
Power train skeleton
Drive shaft
Torque converter and transmission hydraulic piping
Brake cooling oil control valve (BCV)
Torque converter
Show all 248 sections
Torque converter valve
Transmission
Transmission control valve
ECMV
Axle
Differential
Final drive
Wheels
Steering column
Steering linkage
Brake piping
Brake valve
Secondary brake valve
Relay valve41 topics
- Front brake off valve
- Accumulator charge valve
- Accumulator
- Slack adjuster
- Brake
- Parking brake solenoid valve
- Suspension
- Suspension cylinder
- Rear axle support
- Steering and hoist hydraulic piping
- Dump body control
- Hydraulic tank
- Steering valve
- Crossover relief valve
- Steering cylinder
- Steering control valve
- Hoist valve
- Dump control valve (EPC valve)
- Hoist cylinder
- Hydraulic pump
- Auto greasing system
- ROPS cab
- Air conditioner
- Rear view monitor
- Machine monitor system
- Automatic shift control system
- Transmission controller
- External power supply heater
- Automatic emergency steering system
- Automatic suspension system
- Retarder control system
- Battery disconnector switch
- Dump control lever
- Payload meter (Card type)
- VHMS controller related
- ASR system (If equipped)
- Sensors, switches
- Standard value table for engine
- Standard value table for machine
- Tools for testing, adjusting, and troubleshooting
- Sketch of special tool
Testing engine speed
Testing air supply pressure (boost pressure)
Testing exhaust temperature
Testing exhaust gas color
Adjustment of valve clearance
Testing of compression pressure
Testing blow-by pressure
Testing engine oil pressure
Testing EGR valve and bypass valve drive oil pressure
Handling of fuel system devices
Releasing residual pressure from fuel system
Testing of fuel pressure
Reduced cylinder mode operation
No-injection cranking
Testing of fuel return rate and fuel leakage
Bleeding air from fuel circuit
Testing the fuel circuit for leakage
Replacement and adjustment of fan belt
Replacement and adjustment of alternator and air conditioner compressor belt
Testing torque converter stall speed
Testing power train oil pressure
Adjusting transmission speed sensor
Testing and adjusting brake oil pressure1 topic
- with nitrogen gas
Testing brake performance
Bleeding air from brake circuit
Testing wear of front brake pad
Testing wear of rear brake disc
Method of releasing parking brake in an emergency
Testing and adjusting front suspension cylinder
Testing and adjusting rear suspension cylinder
Testing and adjusting front suspension cylinder (Automatic suspension specification)
Testing and adjusting hydraulic pressure in steering, hoist circuit
Testing and adjusting oil pressure in dump EPC circuit
Air bleeding from steering cylinder
Procedure for raising dump body in emergency
Procedure for lowering dump body in emergency
Adjusting body positioner sensor
Resetting method for dump body seating control
Handling of voltage circuit of engine controller
Adjusting transmission controller
Method for emergency escape at electrical system failure
Setting and adjusting of devices
Special functions of machine monitor (EMMS)
Request for opening ORBCOMM terminal
VHMS controller initial setting procedure
Using method of KOMTRAX functions of ORBCOMM terminal
Precautions for replacing VHMS controller
Pm Clinic check sheet
Initial setting of payload meter
Setting of payload meter built in VHMS52 topics
- Setting of card-type payload meter (PLM- ) after installation or replacement
- Points to remember when troubleshooting
- Sequence of events in troubleshooting
- Check before troubleshooting
- Classification and procedures for troubleshooting
- Contents of troubleshooting table
- Connection table for connector pin numbers
- T-branch box and T-branch adapter table
- Failure codes table
- Fuse locations
- Failure code [1500L0] (Dual engagement)
- Failure code [15B0NX] (Transmission oil filter: Clogging)
- Failure code [15F0KM] (R o F shifting abuse 1: Mistake in operation)
- Failure code [15F0MB] (R o F shifting abuse 2: Mistake in operation)
- Failure code [15F7KM] (Forward clutch disk abuse: Mistake in operation or setting)
- Failure code [15G0MW] (R clutch: Slipping)
- Failure code [15G7KM] (Reverse clutch disk abuse: Mistake in operation or setting)
- Failure code [15H0MW] (Hi clutch: Slipping)
- Failure code [15J0MW] ( Lo clutch: Slipping)
- Failure code [15K0MW] (1st clutch: Slipping)
- Failure code [15L0MW] (2nd clutch: Slipping)
- Failure code [15M0MW] (3rd clutch: Slipping)
- Failure code [15N0MW] (4th clutch: Slipping)
- Failure code [15SBL1] (R clutch solenoid: Fill signal is ON when command current is OFF)
- Failure code [15SBMA] (R clutch solenoid: Malfunction)
- Failure code [15SCL1] (Hi clutch solenoid: Fill signal is ON when command current is OFF)
- Failure code [15SCMA] (Hi clutch solenoid: Malfunction)
- Failure code [15SDL1] (Lo clutch solenoid: Fill signal is ON when command current is OFF)
- Failure code [15SDMA] (Lo clutch solenoid: Malfunction)
- Failure code [15SEL1] (1st clutch solenoid: Fill signal is ON when command current is OFF)
- Failure code [15SEMA] (1st clutch solenoid: Malfunction)
- Failure code [15SFL1] 2nd clutch solenoid: Fill signal is ON when command current is OFF
- Failure code [15SFMA] 2nd clutch solenoid: Malfunction
- Failure code [15SGL1] 3rd clutch solenoid: Fill signal is ON when command current is OFF
- Failure code [15SGMA] 3rd clutch solenoid: Malfunction
- Failure code [15SHL1] 4th clutch solenoid: Fill signal is ON when command current is OFF
- Failure code [15SHMA] 4th clutch solenoid: Malfunction
- Failure code [15SJMA] Lockup clutch solenoid: Malfunction
- Failure code [2C4MNX] Retarder cooling oil filter: Clogging
- Failure code [2F00KM] Parking brake: Mistake in operation or setting
- Failure code [2G42ZG] Accumulator: Oil pressure reduction (Front)
- Failure code [2G43ZG] Accumulator: Oil pressure reduction (Rear)
- Failure code [6014NX] Hydraulic oil filter: Clogging
- Failure code [989A00] Engine over run prevention command signal: Operating
- Failure code [989D00] Rear section tipping over alarm: Alarm is activated
- Failure code [A570NX] Engine oil filter: Clogging
- Failure code [AA10NX] Air cleaner element: Clogging
- Failure code [AB00MA] Alternator: Malfunction
- Failure code [B@BAZG] Abnormal lowering of engine oil pressure: Lowering of oil pressure
- Failure code [B@BAZK] Engine oil: Level too low
- Failure code [B@BCNS] Engine: Overheat
- Failure code [B@BCZK] Lowering of radiator coolant: Lowering of level
Failure code [B@BFZK] Lowering of fuel level
Failure code [B@C7NS] Brake cooling oil: Overheating (Rear)
Failure code [B@CENS] Overheating of torque converter oil
Failure code [B@GAZK] Battery electrolyte level: Lowering of level
Failure code [B@JANS] Steering oil temperature: Overheat
Failure code [CA111] Abnormality in engine controller
Failure code [CA115] Engine Ne or Bkup speed sensor error
Failure code [CA122] Charge (boost) pressure sensor high error
Failure code [CA123] Charge (boost) pressure sensor low error
Failure code [CA131] Throttle sensor high error
Failure code [CA132] Throttle sensor low error
Failure code [CA135] Engine oil pressure sensor high error
Failure code [CA141] Engine oil pressure sensor low error
Failure code [CA144] Coolant temperature sensor high error
Failure code [CA145] Coolant temperature sensor low error
Failure code [CA153] Charge (boost) temperature sensor high error
Failure code [CA154] Charge (boost) temperature sensor low error
Failure code [CA187] Sensor power supply 2 low error
Failure code [CA212] Engine oil temperature sensor high error
Failure code [CA213] Engine oil temperature sensor low error
Failure code [CA221] Atmospheric pressure sensor high error
Failure code [CA222] Atmospheric pressure sensor low error
Failure code [CA227] Sensor power supply 2 high error
Failure code [CA234] Engine overspeed
Failure code [CA238] Ne speed sensor power supply error
Failure code [CA263] Fuel Temp Sensor High Error
Failure code [CA265] Fuel Temp Sensor Low Error
Failure code [CA271] PCV1 Short circuit
Failure code [CA272] PCV1 Disconnection
Failure code [CA273] PCV2 Short circuit
Failure code [CA274] PCV2 Disconnection
Failure code [CA322] Injector #1 open/short error
Failure code [CA323] Injector #5 open/short error
Failure code [CA324] Injector #3 open/short error
Failure code [CA325] Injector #6 open/short error
Failure code [CA331] Injector #2 open/short error
Failure code [CA332] Injector #4 open/short error
Failure code [CA342] Calibration code inconsistency
Failure code [CA351] Injectors drive circuit error
Failure code [CA352] Sens Supply 1 Volt Low Error
Failure code [CA386] Sensor power supply 1 high error
Failure code [CA431] Idle validation switch error
Failure code [CA432] Idle validation action error
Failure code [CA441] Battery voltage low error
Failure code [CA442] Battery voltage high error
Failure code [CA449] Common rail pressure high error 2
Failure code [CA451] Rail Press Sensor High Error
Failure code [CA452] Rail Press Sensor Low Error
Failure code [CA553] Common rail pressure high error 1
Failure code [CA554] Common rail pressure sensor in range error
Failure code [CA559] Supply pump pressure very low error 1
Failure code [CA689] Engine Ne speed sensor error
Failure code [CA731] Engine Bkup speed sensor phase error
Failure code [CA757] All continuous data lost error
Failure code [CA778] Engine Bkup speed sensor error
Failure code [CA1228] EGR valve servo error 141 topics
- Failure code [CA1625] EGR valve servo error 2
- Failure code [CA1626] (Bypass valve solenoid current high error)
- Failure code [CA1627] (Bypass valve solenoid current low error)
- Failure code [CA1628] Bypass Valve Servo Error 1
- Failure code [CA1629] Bypass Valve Servo Error 2
- Failure code [CA1631] (Bypass valve lift sensor high error)
- Failure code [CA1632] (Bypass valve lift sensor low error)
- Failure code [CA1633] KOMNET datalink timeout error
- Failure code [CA2185] Throttle sensor supply voltage high error
- Failure code [CA2186] Throttle sensor power supply low error
- Failure code [CA2249] Supply pump pressure very low error 2
- Failure code [CA2271] EGR valve lift sensor high error
- Failure code [CA2272] EGR valve lift sensor low error
- Failure code [CA2351] EGR valve solenoid operation short circuit
- Failure code [CA2352] EGR valve solenoid operation disconnect
- Failure code [CA2555] Intake air heater relay open circuit error
- Failure code [CA2556] Intake air heater relay short circuit error
- Failure code [D19HKB] Stop lamp relay output system: Short circuit
- Disconnection, short circuit or short circuit to power supply line
- Failure code [DAF9KM] Wrong connection of connector
- Abnormal communication
- Lowering of supply voltage
- Abnormality in controller
- Power supply voltage too low
- Failure code [DAQ9KQ] Transmission controller: Disagreement of model selection
- Failure code [DAQRKR] Abnormality in CAN communication (Transmission)
- Failure code [DAQRMA] Transmission controller option setting: Malfunction
- Failure code [DAQV00] Neutral coast caution
- Failure code [DAQW00] Neutral over speed caution
- Failure code [DB10KT] Retarder controller nonvolatile memory: Abnormality in controller
- Power supply system trouble
- Power supply voltage too low
- Failure code [DB19KQ] Disagreement of model selection (Retarder controller)
- Failure code [DB1RKR] CAN communication (retarder controller): Communication disabled
- Failure code [DB1RMA] Disagreement of option setting (Retarder controller)
- Failure code [DB2RKR] CAN communication (engine controller): Communication disabled
- Low power supply voltage (input)
- Disagreement of model selection signals
- power supply: Low power supply voltage (input)
- power supply output: Low output voltage
- communication: Defective communication (Abnormality in target component system)
Failure code [DBBRKR] Abnormality in CAN communication (VHMS)
Failure code [DBC2KK] ABS controller solenoid power supply: Power supply system trouble1 topic
- Power supply voltage too low
Failure code [DBC9KQ] Disagreement of model selection (ABS controller)
Failure code [DBCRKR] Abnormality in CAN communication (ABS)
Failure code [DBCRMA] Disagreement of option setting (ABS controller)1 topic
- Out of input signal range
Failure code [DDD8KA] ARSC system switch system: Disconnection (If equipped)
Failure code [DDD8KB] ARSC system switch system: Short circuit (If equipped)
Failure code [DDD9KA] ABS system switch system: Disconnection
Failure code [DDD9KB] ABS system switch system: Short circuit
Failure code [DDDAKA] ASR system switch: Disconnection
Failure code [DDDAKB] ASR system switch: Short circuit
Failure code [DDP6L4] Service brake pressure switch trouble (Rear)
Failure code [DDTHKA] Hi clutch fill switch: Disconnection
Failure code [DDTJKA] Lo clutch fill switch: Disconnection
Failure code [DDTKKA] 1st clutch fill switch: Disconnection
Failure code [DDTLKA] 2nd clutch fill switch: Disconnection
Failure code [DDTMKA] 3rd clutch fill switch: Disconnection
Failure code [DDTNKA] R clutch fill switch: Disconnection
Failure code [DDTPKA] 4th clutch fill switch: Disconnection
Failure code [DF10KA] Gear shift lever: Disconnection
Failure code [DF10KB] Gear shift lever: Short circuit
Failure code [DGF1KX] Transmission oil temperature sensor: Out of input signal range1 topic
- Ground fault (Rear wheel)
Failure code [DGR6KX] Steering oil temperature sensor: Input signal out of range
Failure code [DGT1KX] Torque converter oil temperature sensor: Out of input signal range10 topics
- sensor (F): Disconnection
- sensor (F): Short circuit
- sensor (R): Disconnection
- sensor (R): Short circuit
- Short circuit
- Short circuit with power supply line
- pressure sensor system (Front right)
- in suspension pressure sensor system (Front right)
- pressure sensor system (Front left)
- fault in suspension pressure sensor system (Front left)
Failure code [DHP6KA] Suspension pressure sensor system: Disconnection (Right rear)52 topics
- Out of input signal range (Right rear)
- sensor system: Short circuit (Right rear)
- sensor system: Disconnection or ground fault (Right rear)
- Failure code [DHP7KA] Suspension pressure sensor system: Disconnection (Left rear)
- Out of input signal range (Left rear)
- sensor system: Short circuit (Left rear)
- sensor system: Disconnection or ground fault (Left rear)
- Failure code [DHT5KX] Torque converter oil pressure sensor: Out of input signal range
- and stop condition with signal
- Failure code [DHU2KX] Front accumulator oil pressure sensor: Out of input signal range
- Failure code [DHU3KX] Rear accumulator oil pressure sensor: Out of input signal range
- Failure code [DHU6KX] Trouble in ABS control valve pressure sensor (Front right)
- Failure code [DHU7KX] Trouble in ABS control valve pressure sensor (Front left)
- Failure code [DHU8KX] Trouble in ABS control valve pressure sensor (Front right)
- Failure code [DHU9KX] Trouble in ABS control valve pressure sensor (Front right)
- Failure code [DHUTKX] Trouble in ABS cut valve pressure sensor
- Failure code [DJF1KA] Fuel level sensor: Disconnection
- Failure code [DK30KX] Steering angle potentiometer: Trouble (Disconnection)
- with swich signal
- Failure code [DK52KX] Failure in hoist lever potentiometer 1: Out of input signal range
- Failure code [DK53L8] Failure in hoist lever potentiometer 2: Disagreement of analog signal
- Failure code [DK54KX] Body positioner sensor: Out of input signal range
- Failure code [DKD0L6] Failure in steering speed sensor
- Failure code [DKH0KX] Clinometer sensor signal out of range
- Failure code [DKH1KX] or VHMS_LED display: "n4"o"33" Abnormality in clinometer sensor
- Failure code [DLF1KA] Transmission input shaft speed sensor: Disconnection
- speed signal
- Failure code [DLF2KA] Transmission intermediate shaft speed sensor: Disconnection
- of revolution speed signal
- Failure code [DLF6KA] Disconnection in wheel speed sensor (Front right)
- Failure code [DLF6L3] Trouble in wheel speed sensor (Front right)
- Failure code [DLF7KA] Disconnection in wheel speed sensor (Front left)
- Failure code [DLF7L3] Trouble in wheel speed sensor (Front left)
- Failure code [DLF8KA] Disconnection in wheel speed sensor (Right rear)
- Failure code [DLF8L3] Trouble in wheel speed sensor (Right rear)
- Failure code [DLF8LC] Trouble in wheel speed sensor system (Right rear)
- Failure code [DLF8MA] Disconnection in wheel speed sensor (Right rear)
- Failure code [DLF9KA] Disconnection in wheel speed sensor (Left rear)
- Failure code [DLF9L3] Trouble in wheel speed sensor (Left rear)
- Failure code [DLF9LC] Trouble in wheel speed sensor system (Left rear)
- Failure code [DLF9MA] Disconnection in wheel speed sensor (Left rear)
- Failure code [DLT3KA] Disconnection in transmission output shaft speed sensor system
- Failure code [DLT3LC] Trouble in transmission output shaft speed sensor
- Failure code [DLT4KA] Disconnection in transmission output shaft speed sensor
- Failure code [DLT4MA] Disconnection in transmission output shaft speed sensor
- Failure code [DV00KB] Short circuit in buzzer output
- Failure code [DW2AKA] Disconnection in main pressure variable valve output
- Failure code [DW2AKB] Ground fault in main pressure variable valve output circuit
- Failure code [DW2AKY] Hot short in main pressure variable valve output circuit
- Failure code [DW2AL1] Defective reset of main pressure variable valve
- Failure code [DW2ALH] Malfunction of main pressure variable valve
- (Disconnection or short circuit)
Failure code [DWNBK4] Trouble in ASR shut-off valve (Valve keeps operating)
Failure code [DWNBKA] Disconnection in ASR shut-off valve output circuit
Failure code [DWNBKB] Ground fault in ASR shut-off valve output circuit
Failure code [DWNBKY] Short circuit in ASR shut-off valve output circuit
Failure code [DWNBMA] Trouble in ASR shut-off valve (Valve does not operate)
Failure code [DWNDKZ] Trouble in ABS cut-off valve (Front) system
Failure code [DWNDMA] Defective ABS cut-off valve (Front)
Failure code [DWNEKZ] Trouble in ABS cut-off valve (Rear) system
Failure code [DWNEMA] Defective ABS cut-off valve (Rear)4 topics
- solenoid valve (Valve keeps operating)
- solenoid valve output circuit
- solenoid valve
- solenoid valve (Valve does not operate)
Failure code [DX13KA] Disconnection in hoist EPC valve output circuit
Failure code [DX13KB] Short circuit in hoist EPC valve output circuit
Failure code [DX13KY] Short circuit in hoist EPC valve output circuit6 topics
- (right) (Valve keeps operating)
- (right) output circuit
- (right) (Valve does not operate)
- (left) (Valve keeps operating)
- (left) output circuit
- (left) (Valve does not operate)
Failure code [DX21KA] Disconnection in ABS control valve output circuit (Front right)
Failure code [DX21KB] Ground fault in ABS control valve output circuit (Front right)
Failure code [DX21KY] Hot short in ABS control valve output circuit (Front right)
Failure code [DX21MA] Defective ABS control valve (Front right)
Failure code [DX22KA] Disconnection in ABS control valve output circuit (Front left)47 topics
- Failure code [DX22KB] Ground fault in ABS control valve output circuit (Front left)
- Failure code [DX22KY] Hot short in ABS control valve output circuit (Front left)
- Failure code [DX22MA] Defective ABS control valve (Front left)
- Failure code [DX23KA] Disconnection in ABS control valve output circuit (Rear right)
- Failure code [DX23KB] Ground fault in ABS control valve output circuit (Rear right)
- Failure code [DX23KY] Hot short in ABS control valve output circuit (Rear right)
- Failure code [DX23MA] Defective ABS control valve (Rear right)
- Failure code [DX24KA] Disconnection in ABS control valve output circuit (Rear left)
- Failure code [DX24KB] Ground fault in ABS control valve output circuit (Rear left)
- Failure code [DX24KY] Hot short in ABS control valve output circuit (Rear left)
- Failure code [DX24MA] Defective ABS control valve (Rear left)
- Failure code [DX25MA] Defective ABS front wheel system control valve
- Failure code [DX26MA] Defective ABS rear wheel system control valve
- Failure code [DXH1KA] Lockup clutch solenoid output circuit: Disconnection
- Failure code [DXH1KB] Lockup clutch solenoid output circuit: Short circuit
- power supply line
- Failure code [DXH2KA] Hi clutch solenoid output circuit: Disconnection
- Failure code [DXH2KB] Hi clutch solenoid output circuit: Short circuit
- Failure code [DXH2KY] Hi clutch solenoid output circuit: Short circuit to power supply line
- Failure code [DXH3KA] Lo clutch solenoid output circuit: Disconnection
- Failure code [DXH3KB] Lo clutch solenoid output circuit: Short circuit
- Failure code [DXH3KY] Lo clutch solenoid output circuit: Short circuit in power supply line
- Failure code [DXH4KA] 1st clutch solenoid output circuit: Disconnection
- Failure code [DXH4KB] 1st clutch solenoid output circuit: Short circuit
- Failure code [DXH4KY] 1st clutch solenoid output circuit: Short circuit to power supply line
- Failure code [DXH5KA] 2nd clutch solenoid output circuit: Disconnection
- Failure code [DXH5KB] 2nd clutch solenoid output circuit: Short circuit
- Failure code [DXH5KY] 2nd clutch solenoid output circuit: Short circuit in power supply line
- Failure code [DXH6KA] 3rd clutch solenoid output circuit: Disconnection
- Failure code [DXH6KB] 3rd clutch solenoid output circuit: Short circuit
- Failure code [DXH6KY] 3rd clutch solenoid output circuit: Short circuit to power supply line
- Failure code [DXH7KA] R clutch solenoid output circuit: Disconnection
- Failure code [DXH7KB] R clutch solenoid output circuit: Short circuit
- Failure code [DXH7KY] R clutch solenoid output circuit: Short circuit to power supply line
- Failure code [DXHHKA] 4th clutch solenoid output circuit: Disconnection
- Failure code [DXHHKB] 4th clutch solenoid output circuit: Short circuit
- Failure code [DXHHKY] 4th clutch solenoid output circuit: Short circuit to power supply line
- Failure code [F@BBZL] or VHMS_LED display: "n3" o "38" Blow-by pressure: High error
- Abnormal heat
- Overheat
- Abnormal heat
- Overheat
- Before troubleshooting of electric system
- Engine does not start
- Automatic preheating does not operate
- Machine monitor does not display all, when starting switch is turned ON
- Machine monitor does not operate when starting switch is OFF
Alarm buzzer does not sound
Alarm buzzer does not stop sounding1 topic
- section do not display properly
A selection of the display in character display section cannot be changed
Power mode selecting function does not operate properly
AISS function does not operate properly
Seat belt caution lamp does not display properly
Turn signal lamp or turning lamp (hazard lamp) do not work properly
Night illumination (lighting) does not work properly
Emergency steering does not operate
Hoist lever does not operate normally
Electric priming pump does not operate or does not stop automatically
Contents of troubleshooting table
Machine does not start
Machine does not travel smoothly (hunting)
Lockup cannot be cancelled
Excessive shock when starting or shifting excessive
Transmission does not shift up
Machine lacks power or speed when traveling
Time lag is excessive when starting or shifting gear
Torque converter oil temperature is high
Torque converter oil pressure is low
Front brake is ineffective
Rear brake is ineffective
Steering wheel is heavy
Steering wheel does not work
Steering wheel vibrates
Dump body lifting speed is slow
Dump body does not work
Excessive hydraulic drift of dump body
Method of using troubleshooting chart
Starting performance of engine is poor
Engine does not start
Engine does not pick up smoothly
Engine stops during operation
Engine does not rotate smoothly
Engine lack output (or lacks power)
Exhaust gas is black (incomplete combustion)
Oil consumption is excessive (or exhaust gas is blue)
Oil becomes dirty quickly
Fuel consumption is excessive
Oil is in coolant (or coolant spurts back or coolant level goes down)
Oil pressure drops
Oil level rises (Entry of coolant or fuel)
Coolant temperature becomes too high (Overheating)
Abnormal noise is made
Vibration is excessive
Air cannot be bled from fuel circuit
How to read this manual
Coating materials list
Special tool list43 topics
- Sketches of special tools
- Removal and installation of fuel supply pump assembly
- Removal and installation of fuel injector assembly
- Removal and installation of cylinder head assembly
- Removal and installation of engine front seal
- Removal and installation of engine rear seal
- Removal and installation of engine assembly
- Removal and installation of radiator assembly
- Removal and installation of output shaft assembly
- Disassembly and assembly of output shaft assembly
- Removal and installation of brake and power train oil cooler assembly
- Removal and installation of torque converter and transmission assembly
- Separation and coupling of transmission assembly and torque converter assembly
- Disassembly and assembly of torque converter and control valve assembly
- Disassembly and assembly of torque converter assembly
- Disassembly and assembly of transmission assembly
- Removal and installation of transmission control valve assembly (ECMV assembly)
- Disassembly and assembly of transmission control valve assembly (ECMV assembly)
- Removal and installation of differential assembly
- Disassembly and assembly of differential assembly
- Removal and installation of final drive carrier assembly
- Disassembly and assembly of final drive carrier assembly
- Disassembly and assembly of front wheel hub assembly
- Disassembly and assembly of steering cylinder assembly
- Removal and installation of front brake caliper pads
- Removal and installation of front brake calipers assembly
- Disassembly and assembly of front brake calipers assembly
- Removal and installation of final drive and rear brake assembly
- Removal and installation of final drive, rear brake, and parking brake assembly
- Disassembly and assembly of final drive, rear brake, and parking brake assembly
- Removal and installation of front wheel assembly
- Removal and installation of rear wheel assembly
- Removal and installation of front suspension cylinder assembly
- Disassembly and assembly of front suspension cylinder assembly (Cylinder with buffer ring)
- Removal and installation of rear suspension cylinder assembly
- Disassembly and assembly of rear suspension cylinder assembly (Cylinder with buffer ring)
- Disassembly and assembly of hoist cylinder assembly
- Removal and installation of body assembly
- Disassembly and assembly of operator's seat assembly
- Removal and installation of air conditioner unit assembly
- Removal and installation of engine controller assembly
- Removal and installation of transmission controller assembly
- Removal and installation of retarder controller assembly
Power train hydraulic circuit diagram
Steering and hoist hydraulic circuit diagram
Brake hydraulic circuit diagram for ASR specification (If equipped)
for ABS + ASR specification (If equipped)
Electrical circuit diagram inside cab
Electrical circuit diagram outside cab
Electrical circuit diagram for VHMS
Electrical circuit diagram for ASR (If equipped)
Electrical circuit diagram for ABS (If equipped)
Air conditioner electrical circuit diagram
Electrical circuit diagram for auto greasing (If equipped)
Connectors table and arrangement drawing
Inside this manual
Real pages from this service manual (1,699 pages). Open the sample pages (PDF, 835 KB)
- Specifications, page 642: 30 Testing and adjusting
- Troubleshooting, page 1,058: Failure code [DGT5KA] or VHMS_LED display: "n3" o "22" Exhaust gas
- Diagram, page 1,240: Failure code [DX22KY] Hot short in ABS control valve output circuit
- Foldout diagram, page 1,683: HD465-7E0, HD605-7E0
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This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 1,699 pages
Quantity one is the manual described above.
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60-day returns
Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy
Binder not included
Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).