Códigos HD605-7

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

a The terms male and female refer to the pins while the terms male housing and female housing refer to the
mating portion of the housing.
No. X-type connector

of T-adapter
pins Male (female housing) Female (male housing)
Part No.
1 Part No.: 08055-00181 Part no.: 08055-00191 799-601-7010
2 799-601-7020
Part No.: 08055-00282 Part No.: 08055-00292
3 799-601-7030
Part No.: 08055-00381 Part No.: 08055-00391
4 799-601-7040
Part No.: 08055-00481 Part No.: 08055-00491

Terminal part no.: 79A-222-3370 Terminal part no.: 79A-222-3390
Electric wire size: 0.85 Electric wire size: 0.85

Grommet: black Grommet: black
Quantity: 20 Quantity: 20
Terminal part no.: 79A-222-3380 Terminal part no.: 79A-222-3410

Grommet: red Grommet: red
20-318 HD465-7, HD605-7

(10)
No. SWP-type connector

of T-adapter
Part No.
6 799-601-7050
Part No.: 08055- 10681 Part No.: Part No.: 08055- 10691
8 799-601-7060
Part No.: 08055-10881 Part No.: 08055- 10891
12 799-601-7310
Part No.: 08055- 11281 Part No.: 08055- 11291
14 799-601-7070
Part No.: 08055- 11481 Part No.: 08055-11491
HD465-7, HD605-7 20-319

(1)
No. SWP-type connector

of T-adapter
Part No.
16 799-601-7320
Part No.: 08055-11681 Part No.: 08055-11691

Terminal part no.: Terminal part no.:

Grommet: black Grommet: black
Terminal part no.: Terminal part no.:

Grommet: red Grommet: red
20-320 HD465-7, HD605-7

(10)
No. M-type connector

of T-adapter
Part No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080
2 799-601-7090
Part No.: 08056-00271 Part No.: 08056-00281
3 799-601-7110
Part No.: 08056-00371 Part No.: 08056-00381
4 799-601-7120
Part No.: 08056-00471 Part No.: 08056-00481
6 799-601-7130
Part No.: 08056-00671 Part No.: 08056-00681
8 799-601-7340
Part No.: 08056-00871 Part No.: 08056-00881
HD465-7, HD605-7 20-321

(7)
S-type connector
No.
of pins T-adapter
Male (female housing) Female (male housing)
Part No.
8 799-601-7140
Part No.: 08056-10871 Part No.: 08056-10881
10
799-601-7150
(white)
Part No.: 08056-11071 Part No.: 08056-11081
12
799-601-7350
(white)
Part No.: 08056-11271 Part No.: 08056-11281
16
799-601-7330
(white)
Part No.: 08056-11671 Part No.: 08056-11681
20-322 HD465-7, HD605-7

(10)
S-type connector
No.
of pins T-adapter
Part No.
10

(blue)
12
799-601-7160
(blue)
Part No.: 08056-11272 Part No.: 08056-11282
16
799-601-7170
(blue)
Part No.: 08056-11672 Part No.: 08056-11682
HD465-7, HD605-7 20-323

(1)
MIC type connector

No.
of pins T-adapter
Part No.
Housing part No.: 79A-222-2640 Housing part No.: 79A-222-2630
7
Qty.: 5 Qty.: 5
11
Qty.: 5 Qty.: 5
5 799-601-2710

Qty.: 5 Qty.: 5
9 799-601-2950

Qty.: 5 Qty.: 5
13 799-601-2720

Qty.: 2 Qty.: 2
20-324 HD465-7, HD605-7

(10)
MIC type connector

No. of
pins T-adapter
Part No.
17 799-601-2730

Qty.: 2 Qty.: 2
21 799-601-2740

Qty.: 2 Qty.: 2

Qty.: 50 Qty.: 50
HD465-7, HD605-7 20-325

(1)
AMP040-type connector
No. of
pins T-adapter
Part No.
8 799-601-7180
Housing part No.: 79A-222-3430

Qty.: 5
12 799-601-7190

Qty.: 5
16 799-601-7210

Qty.: 5
20 799-601-7220

Qty.: 5
aTerminal part No.: 79A-222-3470 (no relation with number of pins)
20-326 HD465-7, HD605-7

(1)
AMP070-type connector
No. of
pins T-adapter
Part No.
10 799-601-7510
Part No.: 7821-92-7330
12 799-601-7520
Part No.: 7821-92-7340
14 799-601-7530
Part No.: 7821-92-7350
18 799-601-7540
Part No.: 7821-92-7360
20 799-601-7550
Part No.: 7821-92-7370
HD465-7, HD605-7 20-327

(9)
L type connector
No. of
pins T-adapter
Part No.
PA type connector
No. of
pins T-adapter
Part No.
Bendix MS connector
No. of
pins T-adapter
Part No.
10 799-601-3460
20-328 HD465-7, HD605-7

(10)
KES 1 (Automobile) connector

No. of
pins T-adapter
Part No.
Part No.: 08027-10210 (natural color) Part No.: 08027-10260 (natural color)
08027-10220 (black) 08027-10270 (black)
Part No.: 08027-10310 Part No.: 08027-10360
08027-10420 (black) 08027-10470 (black)
08027-10620 (black) 08027-10670 (black)
HD465-7, HD605-7 20-329

(1)
KES 1 (Automobile) connector

No. of
pins T-adapter
Part No.
08027-10820 (black) 08027-10870 (black)
20-330 HD465-7, HD605-7

(1)
Connector for relay (socket type)

No. of
pins T-adapter
Part No.
5 799-601-7360
6 799-601-7370
HD465-7, HD605-7 20-331

(10)
F-type connector
No. of
pins T-adapter
Part No.
20-332 HD465-7, HD605-7

(1)
[The pin No. is also marked on the connector (electric wire insertion end)]
Type HD30 series connector

(shell size T-adapter
code) Body (plug) Body (receptacle)
Part No.
Pin (male terminal) Pin (female terminal)
Part No.: 08191-11201, 08191-11202, Part No.: 08191-14101, 08191-14102,

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
799-601-9210
(1) Pin (female terminal) Pin (male terminal)
Part No.: 08191-12201, 08191-12202, Part No.: 08191-13101, 08191-13102,

08191-12205, 08191-12206 08191-13105, 08191-13106
Part No.: 08191-21201, 08191-12202, Part No.: 08191-24101, 08191-24102

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220
Part No.: 08191-22201, 08191-22202, Part No.: 08191-23101, 08191-23102,

08191-22205, 08191-22206 08191-23105, 08191-23106
HD465-7, HD605-7 20-333

(10)

Part No.
18-20 Part No.: 08191-31201, 08191-31202 Part No.: 08191-34101, 08191-34102

799-601-9230
Part No.: 08191-32201, 08191-32202 Part No.: 08191-33101, 08191-33102

18-21 Part No.: 08191-41201, 08191-42202 Part No.: 08191-44101, 08191-44102

799-601-9240
Part No.: 08191-42201, 08191-42202 Part No.: 08191-43101, 08191-43102
20-334 HD465-7, HD605-7

(10)

Part No.
24-9 Part No.: 08191-51201, 08191-51202 Part No.: 08191-54101, 08191-54102

799-601-9250
Part No.: 08191-52201, 08191-52202 Part No.: 08191-53101, 08191-53102

Part No.: 08191-61201, 08191-62202 Part No.: 08191-64101, 08191-64102

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260
Part No.: 08191-62201, 08191-62202, Part No.: 08191-63101, 08191-63102,

08191-62205, 08191-62206 08191-63105, 08191-63106
HD465-7, HD605-7 20-335

(10)

Part No.
Part No.: 08191-71201, 08191-71202, Part No.: 08191-74101, 08191-74102,

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270
Part No.: 08191-72201, 08191-72202, Part No.: 08191-73101, 08191-73102,

08191-72205, 08191-72206 08191-73105, 08191-73106
Part No.: 08191-81201, 08191-81202, Part No.: 08191-84101, 08191-84102,

08191-81203, 08191-81204, 08191-81205, 08191-84103, 08191-84104, 08191-84105,
24-22 08191-81206 08191-84106
799-601-9280
Part No.: 08191-82201, 08191-82202, Part No.: 08191-83101, 08191-83102,

08191-82203, 08191-82204, 08191-82205, 08191-83103, 08191-83104, 08191-83105,
08191-82206 08191-83106
20-336 HD465-7, HD605-7

(10)

Part No.
Part No.: 08191-91203, 08191-91204, Part No.: 08191-94103, 08191-94104,

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290
Part No.: 08191-92203, 08191-92204, Part No.: 08191-93103, 08191-93104,

08191-92205, 08191-92206 08191-93105, 08191-93106
HD465-7, HD605-7 20-337

(10)
DT series connector
No. of
pins T-adapter
Body (plug) Body (receptacle)
Part No.
2 799-601-9020
Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
20-338 HD465-7, HD605-7

(10)
DT series connector
No. of
pins T-adapter
Part No.
8Gr: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8Br: 799-601-9090
12Gr: 799-601-9110
12B: 799-601-9120
12 12G: 799-601-9130
12Br: 799-601-9140
HD465-7, HD605-7 20-339

(10)
DTM series connector

No. of
pins T-adapter
Part No.
2 799-601-9010
Part No.: 08192-02200 Part No.: 08192-02100
DTHD series connector

No. of
pins T-adapter
Part No.
Part No.: 08192 - 31200 (contact size #12) Part No.: 08192 - 31100 (contact size #12)
08192 - 41200 (contact size #8) 08192 - 41100 (contact size #8)
08192 - 51200 (contact size #4) 08192 - 51100 (contact size #4)
20-340 HD465-7, HD605-7

(10)
DRC26 Series connector

No.of
pins T-adapter Part
No.
24 799-601-9360
Part No.: 7821-93-3110
40
799-601-9350
(A)
Part No.: 7821-93-3120
40
799-601-9350
(B)
Part No.: 7821-93-3130
HD465-7, HD605-7 20-340-1

(9)
TROUBLESHOOTING T-ADAPTER TABLE
T-ADAPTER TABLE
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
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
Port No. Connector type Pin No.

799-601-2600 For measuring box Econo-21P Q Q Q Q Q Q
799-601-3100 For measuring box MS-37P Q
799-601-3200 For measuring box MS-37P Q
799-601-3300 For measuring box Econo-24P Q
799-601-3360 Plate For MS box
799-601-3410 BENDIX(MS) 24P Q Q
799-601-3420 BENDIX(MS) 24P Q Q
799-601-3430 BENDIX(MS) 17P Q Q
799-601-3440 BENDIX(MS) 17P Q Q
799-601-3450 BENDIX(MS) 5P Q Q
799-601-3460 BENDIX(MS) 10P Q Q
799-601-3510 BENDIX(MS) 5P Q Q
799-601-3520 BENDIX(MS) 14P Q Q
799-601-3530 BENDIX(MS) 19P Q Q
799-601-2910 BENDIX(MS) 14P Q Q
799-601-3470 CASE Q
799-601-2710 MIC 5P Q Q Q Q
799-601-2720 MIC 13P Q Q Q Q
799-601-2730 MIC 17P Q Q Q Q Q Q Q
799-601-2740 MIC 21P Q Q Q Q Q Q Q
799-601-2950 MIC 9P Q Q Q Q
799-601-2750 ECONO 2P Q Q
799-601-2760 ECONO 3P Q Q
799-601-2770 ECONO 4P Q Q
799-601-2780 ECONO 8P Q Q
799-601-2790 ECONO 12P Q Q
799-601-2810 DLI 8P Q Q
799-601-2820 DLI 12P Q Q
799-601-2830 DLI 16P Q Q
799-601-2840 Extension cable Q Q Q
799-601-2850 CASE Q
799-601-7010 X 1P Q Q
799-601-7020 X 2P Q Q Q Q
799-601-7030 X 3P Q Q Q Q
799-601-7040 X 4P Q Q Q Q
799-601-7050 SWP 6P Q Q Q
799-601-7060 SWP 8P Q Q Q
799-601-7310 SWP 12P Q
799-601-7070 SWP 14P Q Q
HD465-7, HD605-7 20-341

(12)
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
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

799-601-7320 SWP 16P Q
799-601-7080 M 1P Q Q
799-601-7090 M 2P Q Q Q Q
799-601-7110 M 3P Q Q Q Q
799-601-7120 M 4P Q Q Q Q
799-601-7130 M 6P Q Q Q Q
799-601-7340 M 8P Q
799-601-7140 S 8P Q Q Q Q
799-601-7150 S 10P-White Q Q Q Q
799-601-7160 S 12P-Blue Q Q Q
799-601-7170 S 16P-Blue Q Q Q Q
799-601-7330 S 16P-White Q
799-601-7350 S 12P-White Q
799-601-7180 AMP040 8P Q
799-601-7190 AMP040 12P Q Q
799-601-7210 AMP040 16P Q Q Q Q
799-601-7220 AMP040 20P Q Q Q Q
799-601-7230 Short connector X-2 Q Q Q Q
799-601-7240 Case Q Q
799-601-7270 Case Q
799-601-7510 070 10P Q
799-601-7520 070 12P Q
799-601-7530 070 14P Q
799-601-7540 070 18P Q
799-601-7550 070 20P Q
799-601-7360 Relay connector 5p Q
799-601-7370 Relay connector 6p Q
799-601-7380 JFC connector 2P Q
799-601-9010 DTM 2P Q Q
799-601-9020 DT 2P Q Q
799-601-9030 DT 3P Q Q
799-601-9040 DT 4P Q Q
799-601-9050 DT 6P Q Q
799-601-9060 DT 8P-Gray Q Q
799-601-9070 DT 8P-Black Q Q
799-601-9080 DT 8P-Green Q Q
799-601-9090 DT 8P-Blown Q Q
799-601-9110 DT 12P-Gray Q Q
799-601-9120 DT 12P-Black Q Q
799-601-9130 DT 12P-Green Q Q
799-601-9140 DT 12P-Blown Q Q
799-601-9210 HD30 18-8 Q Q
799-601-9220 HD30 18-14 Q Q
20-342 HD465-7, HD605-7

(12)
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
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

799-601-9230 HD30 18-20 Q Q
799-601-9240 HD30 18-21 Q Q
799-601-9250 HD30 24-9 Q Q
799-601-9260 HD30 24-16 Q Q
799-601-9270 HD30 24-21 Q Q
799-601-9280 HD30 24-23 Q Q
799-601-9290 HD30 24-31 Q Q
799-601-9310 Plate For HD30 Q Q Q
799-601-9320 For measuring box For DT, HD Q Q Q
799-601-9330 Case Q
799-601-9340 Case Q
799-601-9350 DRC26 40P Q
799-601-9360 DRC26 24P Q
799-601-9410 For NE, G sensor 2P Q
For boost pressure,
799-601-9420 fuel 3P Q
799-601-9430 PVC socket 2P Q
HD465-7, HD605-7 20-343

(12)
TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS
TYPES AND LOCATIONS OF CONNECTORS

Address
Con- Type Num- 3-dimen-
nector of ber Location sional System diagram
No. connector of pin wiring
diagram ENG TM BK PLM MON VHMS ASR
01 Terminal 1 Battery relay (B) B9 J-1 K-8 H-9 K-9 N-9
02 Terminal 1 Battery relay (M) B9 J-1 K-8 H-8 K-8 N-8
03 Terminal 1 Battery relay (B) B9 J-1 K-8 H-8 K-8 N-8
04 Terminal 1 Battery relay (M) B9 J-1 K-8 H-8 K-8 N-8
05 Terminal 1 Emergency steering relay (B) A8 K-9
06 Terminal 1 Emergency steering relay (M) A8 K-9
07 Terminal 1 Emergency steering relay (B) A8 K-9
08 Terminal 1 Emergency steering relay (M) A9 K-9
11 Terminal 1 Battery relay (E) B8 J-1 K-8 H-9 K-9 N-9
12 Terminal 1 Battery relay (BR) B8 J-1 K-8 H-8 K-8 N-8
12 KES0 2 Washer tank motor J-1 K-8
13 Terminal 1 Battery relay (E) C8 J-1 K-8 H-8 K-8 N-8
14 Terminal 1 Battery relay (BR) C8 H-8 K-8 N-8
15 Terminal 1 Emergency steering relay (E) A8 K-9
16 Terminal 1 Emergency steering relay (BR) A7 K-9
17 Terminal 1 Emergency steering relay (E) B7 K-9
18 Terminal 1 Emergency steering relay (BR) B7 K-8
20 1 Circuit breaker A9 L-8 N-8
21 1 Circuit breaker A9 L-8 N-7
22 1 Circuit breaker A9 J-2 K-8 I-8 L-8 N-8
23 1 Circuit breaker B9 I-2 K-8 I-8 L-8 N-7
1939 HD30 9 Connector for connecting J1939 device G-9 A-3
A One-pin 1 Lamp (Optional for payload meter) J-9

connector
A One-pin 1 Lamp (Optional for payload meter) H-1
connector
A1 M 1 Emergency reset connector X6 B-7
A2 M 1 Emergency reset connector V8 B-7
AAPR PACKARD 3 Air pressure sensor AH5 B-1
ABS M 6 ABS system switch O2 E-9
AC1 One-pin
connector 1 Air conditioner wiring harness M3 C-7
ACBM YAZAKI 2 Air conditioner blower motor T2 A-9
ACCF DT-T 3 ACC oil pressure sensor (Front) L4 L-2 K-4
ACCR DT-T 3 ACC oil pressure sensor (Rear) K3 L-2 K-4
ACM1 AMP 5 Temperature regulation servomotor V3 A-8
ACM2 AMP 5 Air outlet mode selection servomotor M6 B-9
20-344 HD465-7, HD605-7

(10)
Address
Con- Type Num-
3-dimen-
Recirculated/Fresh air selection
ACM3 AMP 5 servomotor W3 A-7
ACP1 AMP 16 Air conditioner control panel O7 B-9
ACP2 AMP 12 Air conditioner control panel O7 B-9
ACPS SUMITOMO 2 Air conditioner pressure switch U2 A-8
ACR1 Relay 4 Blower main relay W3 A-8
ACR2 Relay 4 Blower Hi relay W4 A-8
ACR3 Relay 4 Blower M2 relay W4 A-7
ACR4 Relay 4 Blower M1 relay W4 A-7
ACR5 Relay 4 Compressor clutch relay W4 A-7
ACRE AMP 4 Air conditioner blower resistor U2 A-8
ACTH YAZAKI 2 Thermistor U3 A-8
AISS M 6 AISS switch M3 L-5
ARC M 3 ARSC set switch P8 F-9
ARSC M 6 ARSC system switch N3 C-1 F-9
AS1 SWP 6 Acceleration sensor N2 L-2
AS2 X 3 Acceleration sensor O2 C-8
ASR M 6 ASR system switch O2 F-9 F-5
ASR1 DT-T-T 2 Steering angle sensor C2 C-9
ASR2 DT-T-T 2 Shut off valve L2 D-9
ASR3 DT-T-T 2 ASR valve (R) K3 D-9
ASR4 DT-T-T 2 ASR valve (L) L3 E-9
ASR5 DT-T 2 ASR oil pressure switch (R) K3 E-9
ASR6 DT-T 2 ASR oil pressure switch (L) L2 F-9
ASR7 DT-T 2 ASR oil ptessure switch (Main) K1 F-9
ASS DT-T 2 Air suspension seat T2
ATC1 MIC 17 Transmission controller Z1 L-8 A-7 E-1 E-1 H-1
ATC2 MIC 21 Transmission controller Z1 A-7
ATC3A AMP040 20 Transmission controller Z4 L-8 A-6 E-1 E-1
ATC3B AMP040 16 Transmission controller Z4 A-6 E-1
ATC4 AMP040 12 Transmission controller AA4 L-7 A-5 E-1 F-1 I-1
ATC5A AMP040 20 Transmission controller AA1 L-7 A-5
ATC5B AMP040 16 Transmission controller AA4 A-4
ATC6 X 4 Software rewriting connector

(Transmission controller) W4 A-3
B01 DT-T 6 Intermediate connector K9 M-5
B02 DT-T 6 Intermediate connector K8 M-5
HD465-7, HD605-7 20-345

(5)
Address
B03 DT-T 6 Winker lamp, stop lamp, tail lamp J9 M-6
B04 Terminal 1 Backup lamp J9 F-9 M-6
B05 Terminal 1 Backup alarm buzzer J9 F-9 M-6
B06 Terminal 1 Backup alarm buzzer J9 F-9 M-6
B07 DT-T 3 Body position sensor K9 K-5
B1 One-pin
connector 1 Lamp (Payload meter) (If equipped) I-9
B1 One-pin 1 Lamp (Payload meter) (If equipped) H-1

connector
B10 Terminal 1 Grounding K8 G-9 M-4
B11 Terminal 1 Grounding L8 M-5
B2 One-pin 1 Lamp (Payload meter) (If equipped) J-9

connector
B2 One-pin
connector 1 Lamp (Payload meter) (If equipped) H-1
B3 One-pin 1 Lamp (Payload meter) (If equipped) J-9

connector
B3 One-pin 1 Lamp (Payload meter) (If equipped) H-1
connector
BCOM One-pin 1 Beacon lamp T9 A-2
connector
BK DT-T
(Gray) 8 Intermediate connector F9 H-2 M-2
BL One-pin 1 Intermediate connector C7 I-8

connector
BLS M 6 Rotary lamp switch (If equipped) N1 C-9
BR One-pin 1 Air conditioner wiring harness M4 C-7

connector
BRC1 MIC 17 Retarder controller Y2 J-9 C-1 A-8 D-1 H-1
BRC2 MIC 21 Retarder controller Y2 A-7 A-1
BRC3A AMP040 20 Retarder controller Y4 C-1 A-6 D-1 B-1
BRC3B AMP040 16 Retarder controller Y4 A-5
BRC4 AMP040 12 Retarder controller Z4 J-9 C-1 A-5 D-1 H-1
BRC5A AMP040 20 Retarder controller Y1 A-4
BRC5B AMP040 16 Retarder controller Y2 C-1 A-3 D-1
BRC6 X 4 Software rewriting connector

(Retarder controller) S9 A-2
BT DT 6 Intermediate connector C9 I-2 H-6 G-8 J-6 M-9
BT1 Fuse box X5 E-3 E-7 K-3
BT2 Fuse box X7 L-4 E-2 F-3 E-7 I-3 F-4
BT3 Fuse box X6 L-4 E-2 F-3 E-6 K-3
BT4 Fuse box X6 L-3 E-2 E-6 I-3
BZ2 M 2 Buzzer R1 D-9
CAB1 DT-T 8 Intermediate connector Q9 F-1

(Gray)
CAB2 DT-T 8 Intermediate connector Q9 B-9
(Black)
CAN DT 3 CAN connector AJ6 H-9 L-6 M-3 A-2
20-346 HD465-7, HD605-7

(10)
Address
CAN1 DT-T 3 VHMS CAN connector T9 C-9
CAN2 DT-T 3 Resistor Q1 F-9 D-9
CG1 One-pin 1 Cigarette lighter M5

connector
CG2 1 Cigarette lighter M5
CH1 S 8 Machine monitor mode selector switch 1 M1 E-9
CH2 S 8 Machine monitor mode selector switch 2 M1 E-9
CJA DT-T 6 Joint connector D8 L-9
CJB DT-T 8 Joint connector B7 I-1 M-9

(Black)
CJB DT-T 6 Joint connector E8 L-9
CJC DT-T 6 Joint connector D8 G-8 H-9
CJD DT 6 Joint connector D8 H-9 H-9 M-9
CJE2 DT-T 6 Joint connector AI9 G-1 M-1
CJE3 DT-T 8 Joint connector A12 G-1 M-1 L-3 K-1 N-7
(Black)
DT-T
CJH1 (Black) 8 Joint connector I-9 J-1 M-1
CJH2 DT-T 6 Joint connector J-1 J-1
CJK DT 6 Joint connector B8 I-1 J-9 H-9 J-9 M-9
CJL DT-T 6 Joint connector L7 H-9 I-1 M-1
CJN DT (Black) 8 Joint connector J3 I-1
CJP DT-T 6 Joint connector I9 I-1 J-1
CJP1 DT-T 6 Joint connector H9 I-1
CJP2 DT-T 6 Joint connector I9 H-1
CJPR DT-T 6 Joint connector C8 I-9
CJS DT-T 6 Joint connector L7 N-5
CJSL DT-T 6 Joint connector I9 I-1
CJT DT 8 Joint connector L8 G-9 N-5

(Black)
CJT1 DT-T 8 Joint connector L7 G-1
(Black)
CJT2 DT-T 6 Joint connector H9 G-1
CJW DT-T 6 Joint connector F-7
CK1 YAZAKI 6 Bulb breakage check switch M2 F-9
CLTP PACKARD 2 Coolant temperature sensor AE8 A-1
CM DT-T 8 Lighting switch, passing switch, turn Q8 B-2

(Green) switch
CN3 DT-T 2 Input shaft speed sensor AC9 M-8
CN4 DT-T 2 Intermediate shaft speed sensor AC9 M-8
CN5 DT-T 2 Output shaft speed sensor AD7 M-8 G-2 K-4
CN6 DT-T 2 Solenoid for transmission 1st clutch AB9 M-6
HD465-7, HD605-7 20-347

(10)
Address
CN7 DT-T 2 Fill switch for transmission 1st clutch AB9 N-6
CN8 DT-T 2 Solenoid for transmission 2nd clutch AB9 M-6
CN9 DT-T 2 Fill switch for transmission 2nd clutch AA9 N-6
CN10 DT-T 2 Solenoid for transmission R clutch AA9 M-6
CN11 DT-T 2 Fill switch for transmission R clutch AA9 N-6
CN12 DT-T 2 Solenoid for transmission 3rd clutch AA9 M-6
CN13 DT-T 2 Fill switch for transmission 3rd clutch AA9 N-6
CN14 DT-T 2 Solenoid for transmission 4th clutch AA9 M-5
CN15 DT-T 2 Fill switch for transmission 4th clutch Z9 M-5
CN16 DT-T 2 Solenoid for transmission L clutch Z8 M-7
CN17 DT-T 2 Fill switch for transmission L clutch Z8 N-6
CN18 DT-T 2 Solenoid for transmission H clutch Y8 M-7
CN19 DT-T 2 Fill switch for transmission H clutch Y7 N-7
CN20 DT-T 2 Solenoid for torque converter lockup Z8 M-7

clutch
CN21 DT-T 2 Fill switch for torque converter lockup
clutch Z8 N-7
CN22 DT-T 3 Torque converter intermediate pres- Z5 M-8

sure sensor
CN23 DT-T 2 Torque converter oil temperature AA5 M-7
sensor
CN24 DT-T 2 Transmission valve oil temperature AC5 M-7
sensor
CNS1 DT-T 12 Intermediate connector H-8
(Brown) (Power window switch)
CNS2 DT-T 12 Intermediate connector B-9 B-2 H-8
(Green) (Gear shift lever)
DT-T Intermediate connector
CNS3 (Black) 12 (Parking brake switch) A-9 E-7
COM One-pin
connector 1 Air conditioner wiring harness M3 C-7
D01 DT-T 2 Diode W8 L-5 C-9 F-8 F-8 I-9
D02 DT-T 2 Diode W8 A-1 F-1
D03 DT-T 2 Diode W8 F-1
D04 DT-T 2 Diode M6 A-8
D05 DT-T 2 Diode V8 A-1 E-1
D07 DT-T 2 Diode P2 I-9
D08 DT-T 2 Diode W8 K-5 C-9 F-8 F-8 I-9
DL DT-T 12 Intermediate connector X6

(Black)
DPC1 AMP070 20 Machine monitor P8 I-9 E-9 C-1 A-7
DPC2A AMP070 18 Machine monitor P1 A-6
DPC2B AMP070 12 Machine monitor P1 C-1 A-6 F-1
DPC3A AMP070 18 Machine monitor P8 A-5
DPC4 AMP070 12 Machine monitor Q1 I-9 E-9 D-9 A-5
20-348 HD465-7, HD605-7

(10)
Address
DPC6 AMP040 8 Machine monitor O7
DPC7 X 4 Software rewriting connector N3

(Machine monitor)
DSL 1 Door switch (Left) F1
DSR 1 Door switch (Right) T2
DT7 DT-T 12 Intermediate connector T2 D-2 F-1
DT8 DT-T 4 Intermediate connector J2
E Terminal 1 Emergency steering motor L-9
E01 Terminal 1 Alternator AE7 H-1 N-3 L-4 K-3 N-7
E02A DT-T 2 Starting motor AH1 H-2 M-3
E02B DT-T 2 Starting motor AH1 G-2 M-2
E03 DT-T 2 Engine speed sensor AF1 N-3
E04 DT-T 2 Oil level switch (If equipped) AH5 M-3
E05 Terminal 1 Oil filter switch C2 H-9
E06 Terminal 1 Alternator AE6, H-1 N-4

AF1
E07 DT-T 2 Compressor AF8 N-7
E08 DT-T 2 Diode AG9
E09 Terminal 1 Alternator AE6 H-1 N-3
E10 Terminal 1 Grounding AG9
E11A Terminal 1 Heater relay AJ9 F-3 N-5
E11B Terminal 1 Ribbon heater AH9 F-2 N-4
E12A Terminal 1 Heater relay AJ9 F-3 N-4
E12B Terminal 1 Ribbon heater AG9 F-1 N-4
E13A DTHD 1 Intermediate connector AG1 I-2 K-5

(#4)
E13B DTHD 1 Intermediate connector AG1 H-2 K-5
(#4)
E15 Terminal 1 Grounding AI2 G-1 M-3
E16A Terminal 1 Grounding AI9 F-3 N-5
E16B Terminal 1 Grounding AH9 F-2 N-4
E17A DT-T 2 Diode AJ8 F-3 N-5
E17B DT-T 2 Diode AJ8 F-2 N-4
E2B DT 2 Diode AE5 A-3
ECM A DRC26 40 Engine controller AG5 A-8 L-1 K-8 M-4
ECM B DRC26 40 Engine controller AG9 C-8 L-1 K-8 M-4 B-3
EG4 DT-T 12 Intermediate connector V9

(Brown)
ENG DT-T 8 Intermediate connector AJ7 H-2 H-3 J-7 J-3 M-7
(Gray)
ER Terminal 1 Grounding C9, C8, I-1 J-8 H-8 J-7 M-8
E9, G9
HD465-7, HD605-7 20-349

(10)
Address
ER1 Terminal 1 Grounding P1 D-8 F-7
ER2 Terminal 1 Grounding X7 H-6 A-8 C-1 B-7 F-1
ER3 Terminal 1 Grounding O2
FBC M 6 Front brake cutting switch N3 G-9
FL01 DT-T 2 Radiator coolant level sensor B3 H-9
FL04 YAZAKI 2 Washer motor B3 M-1
FL05 DT-T 2 Air conditioner dual switch B2 L-1
FLB 1 Flasher R1 A-4
FLL 1 Flasher R1 A-4
FLTP PACKARD 2 Fuel temperature sensor AF9 A-1
FOG M 6 Fog lamp switch (If equipped) N1 C-9
FR01 DT-T 2 Air cleaner clogging sensor B7 G-9
FS2 One-pin 2 Spare terminal X6

connector
connector
FS4 One-pin
connector 2 Spare terminal X7

connector
FS8 One-pin 2 Spare terminal X6 J-4
connector
FSO Terminal 1 Fuel shut-off valve AE7 E-1
FSO+ Terminal 1 Fuel shut-off valve + AE7 E-1
FUA Terminal Fuse box (30 A) C9 K-2 L-9 I-9 L-9 N-8
FUB Terminal Fuse box (120 A x 2) C9 K-1 L-9
G One-pin 1 Lamp (Payload meter) (If equipped) I-9

connector
G One-pin 1 Lamp (Payload meter) (If equipped) H-1
connector
G21 Terminal 1 Grounding S1 B-7
GND Terminal 1 Engine block GND AF8 E-2 K-1 L-8 M-4
H01 DT-T 2 Steering flow switch K3
H10 One-pin 1 Heater unit M4

connector
H20 One-pin 1 Heater unit M4
connector
HAZ M 6 Hazard switch O7 G-9
HEAT DT 2 Heater control AJ7 F-6 J-2
HEPC DT-T 2 Hoist EPC valve L5 L-2
HES Terminal 1 Grounding
HN One-pin 1 Horn switch Q8 D-9

connector
HN1A 1 Horn valve A4 L-9
HN1B 1 Horn valve A4 L-9
20-350 HD465-7, HD605-7

(10)
Address
HN2A 1 Horn valve A4
HN2B 1 Horn valve A3
HSL DT-T 4 Intermediate connector V3 D-1
HSL DT-T 4 Hoist lever potentiometer V3 D-1
HSOL DT-T 3 Hoist selector valve L5 L-2
HTA DT-T
(Gray) 8 Intermediate connector L6 I-8 J-3
HTB DT-T 8 Intermediate connector L6 I-8 K-3 J-4 M-2

(Black)
IMPR PACKARD 3 Intake air pressure sensor AF8 B-1
IMTP PACKARD 2 Intake air temperature sensor AF8 B-1
J01 HD30 9 Intermediate connector I2 G-4 F-6 H-7 G-7 I-6
J02 HD30 31 Intermediate connector I2 G-3 F-6 H-7 G-6 I-6 C-7
J03 HD30 31 Intermediate connector I2 F-6 H-6 G-5 I-5 C-7
J04 HD30 31 Intermediate connector H1, H-5 G-4 I-5 C-6

AN6
J05 HD30 31 Intermediate connector H1, F-5 H-4 G-4
AN6
J07 HD30 14 Intermediate connector H1 F-5 H-3 G-4 C-5
J08 HD30 31 Intermediate connector G1 F-5 C-4
J09 HD30 31 Intermediate connector G1 G-6 F-4 H-4 I-5 C-4
J10 HD30 31 Intermediate connector G1 G-4 F-4 H-3 G-3 I-5 C-3
JC01 DT 6 Joint connector AI6 A-4
JC02 DT (Black) 8 Joint connector AI5 A-5
JC03 DT (Black) 8 Joint connector AH5 A-5
JC04 DT (Black) 8 Joint connector AG5 A-6 K-1 L-7 M-4
JC11 DT 6 Joint connector AG5 E-9 K-1
JC12 DT 6 Joint connector AH5 E-9
JC13 DT (Black) 8 Joint connector AI5 F-9 K-1 L-7
JC14 DT (Black) 8 Joint connector AI6 G-9 K-1 L-7 M-3 A-2
JC15 DT 6 Joint connector AI6 H-9 L-1 L-6 M-3
JCA DT-T 8 Joint connector X5 E-1

(Black)
JCB DT-T 8 Joint connector X5 K-6 C-1 A-1 C-1 G-1
(Black)
DT-T
JCC (Black) 8 Joint connector X5 K-6 B-1 A-2 C-1 G-1
JCD DT-T
(Black) 8 Joint connector X4 K-6 B-1 A-1 C-1 G-1
JCE DT-T 8 Joint connector X4 K-7 B-1 A-2 C-1 G-1

(Black)
JCF DT-T
(Black) 8 Joint connector S9 J-8 D-1 A-3 E-1 H-1
JCG DT-T 8 Joint connector V3 K-8 A-3 F-1 F-1 I-1

(Black)
JT1 DT-T 6 Joint connector AD7 J-1
HD465-7, HD605-7 20-351

(10)
Address
JT2 DT-T 6 Joint connector AD7 J-1
LINK DT 6 Data link crossover AJ6 F-7 J-3 K-7
LKO DT-T 2 Intermediate connector U3 D-1
LKO DT-T 2 Lever kick-out solenoid V3 D-1
LP DT (Gray) 12 Intermediate connector I2 H-8 K-2
LS M 3 Rheostat M1 D-9
M Terminal 1 Emergency steering motor K-9
MON1 One-pin
connector 1 Rear view monitor (If equipped) N7 I-9
MON2 One-pin
connector 1 Rear view monitor (If equipped) N7 I-9
MON3 One-pin 1 Rear view monitor (If equipped) O7 I-9

connector
MS11 M 1 Model selection connector U9 A-4
(Transmission controller)
MS32 M 1 Model selection connector V3 A-4
OLPR PACKARD 3 Engine oil pressure sensor AE5 B-1
OP1 M 1 Machine monitor setting connector M8, A-5

N9
N9
O9
M8,
OP4 M 1 Machine monitor setting connector O9 A-5
OP5 M 1 M8,
Machine monitor setting connector O9 A-5
OP6 M 1 Machine monitor setting connector N8, A-5

O8
OP7 M 1 Machine monitor setting connector N8, A-4
O8
OPS DT-T 2 Seat heater T2
PL01 M 2 Left head lamp (LOW) D1 J-1
PL02 M 2 Left head lamp (HIGH) D2 J-1
PL03 One-pin 1 Clearance lamp E1 K-1

connector
PL04 One-pin 1 Clearance lamp E1 K-1
connector
PL05 One-pin 1 Turn signal E1 K-1
connector
PL06 One-pin 1 Fog lamp (If equipped) D1 J-1
connector
PL07 Terminal 1 Grounding D2 K-1
PM1 MIC 21 VHMS wiring harness T9 D-8, F-7,

E-9 D-7 H-7
PM3 DT-T 3 Pitch angle sensor X7 A-4
PM4 S (Natural 16 VHMS wiring harnes T9 I-8 E-7 D-8 C-8 F-6,
color) H-6
20-352 HD465-7, HD605-7

(10)
Address
PM5 MIC 13 Payload meter controller T9 E-9 A-9 G-8
PM6 AMP040 12 Payload meter controller U9 I-8 E-9 D-9 A-9 G-8
PM7 AMP 9 VHMS wiring harnes H-8
PM7 AMP 9 Payload meter controller N7
PM8 BENDIX 5 Connector N7 K-5
PM9 MIC 21 VHMS wiring harness T9 E-9 H-7
PM10 S (Natural 16 VHMS wiring harnes T9 E-9 H-6

color)
PM11 MIC 21 Intermediate connector V9
PMLA DT-T
(Gray) 12 Intermediate connector H9 I-3
PMPR PACKARD 3 Fuel pump pressure sensor AF5 C-1 I-7
PMRA DT-T 6 Intermediate connector D8
POW HD30 21 Intermediate connector AJ7 F-4 H-4 J-7
PR01 M 2 Right head lamp (LOW) A5 K-9
PR02 M 2 Right head lamp (HIGH) A4 J-9
PR03 One-pin 1 Clearance lamp A5 K-9

connector
PR04 One-pin 1 Clearance lamp A5 K-9
connector
PR05 One-pin 1 Turn signal A5 K-9
connector
PR06 One-pin 1 Fog lamp (Optional) A6 J-9
connector
PR07 Terminal 1 Grounding A4 K-8
PSOL DT-T 2 Parking brake solenoid L6 L-3
PSW DT-T 2 Parking brake switch K3 L-3
PUMP PACKARD 3 Fuel pump actuator AF5 D-1

One-pin
PWL connector 1 Power window motor (Left) I2 F-1
PWM M 6 Power mode switch M4 G-9
PWR One-pin 1 Power window motor (Right) C7 F-1

connector
R One-pin
connector 1 Lamp (Payload meter) (If equipped) J-9
R One-pin 1 Lamp (Payload meter) (If equipped) H-1

connector
R01 Relay 5 Engine starting relay AB4 G-7 B-2
R02 Relay 5 Transmission Neutral relay AB3 B-2 A-8
R03 Relay 5 Parking brake relay AB3 A-9
R04 Relay 5 Brake lamp relay (RL) AB3 D-1
R05 Relay 6 Backup lamp, buzzer relay AB2 B-1 D-1
R06 Relay 6 Fog lamp relay AC4 D-1
R07 Relay 5 AISS relay AB4 H-8
R08 Relay 5 Brake lamp relay (CTR) AB3 E-1
HD465-7, HD605-7 20-353

(10)
Address
R09 Relay 5 Brake lamp timer relay AB2 A-9 E-1
R10 Relay 5 PLM GDL relay AC4 A-7
R11 Relay 5 Horn relay AC4 D-1
R14 Relay 5 Brake cutting relay AB4 A-8
R15 Relay 5 Transmission cutting relay A2 B-2
R16 Relay 6 Hazard relay 1 AB1 C-1
R17 Relay 5 Hazard relay 2 AC1 C-1
R19 Relay 5 Parking brake safety relay AC4 A-8
R21 Relay 6 Side lamp relay AC4 A-6
R22 Relay 5 Rotary lamp relay AD3 B-1
R25 YAZAKI 11 Power window relay AC1 B-1
R29 Relay 5 Head lamp Hi relay AD2 C-1
R30 Relay 5 Head lamp Lo relay AD1 B-1
R32 Relay 5 Dust indicator relay AC1 B-3
R33 Relay 6 Parking brake manual switch R9 E-8
R34 YAZAKI 7 Power window switch (Left) S1 H-9
R35 YAZAKI 7 Power window switch (Right) S9 H-9
R37 Relay 5 Auto preheater relay AD3 G-8 B-3
R40 Relay 6 Payload meter relay (If equipped) AD2 A-6
R43 Relay 5 Green outside pilot lamp relay of AD2 A-5

payload meter
Yellow outside pilot lamp relay of
R44 Relay 5 payload meter AD2 A-5
R45 Relay 5 Red outside pilot lamp relay of

payload meter AD1 A-5
RAD YAZAKI 9 AM/FM radio O2
RAIL PACKARD 3 Fuel rail actuator AF5 D-1
RDC YAZAKI 9 Cassette stereo O2
RE1 YAZAKI 2 Resistor S9 C-9 A-8
RE2 YAZAKI 2 Resistor S9 A-7
RE3 YAZAKI 2 Resistor P8 F-9
RE4 YAZAKI 2 Resistor P8 F-9
RESW DT-T 2 Retarder switch L4 L-1 N-1
RETV DT-T 2 Retarder valve L4 L-1
RL YAZAKI 2 Room lamp E9
RL2 One-pin 1 Room lamp 2 G9

connector
RP DT-T 6 Intermediate connector A6 K-8
RPR PACKARD 3 Fuel rail pressure sensor AI6 C-1
20-354 HD465-7, HD605-7

(10)
Address
Con- Type Num-
3-dimen-
RT2 Terminal 1 Emergency steering timer M4
RTL DT-T 6 Retarder potentiometer P8 C-9 C-8
S01 DT-T 2 Service brake switch B7 G-2 N-2
S02 DT-T 2 Secondary brake switch E9 G-2 N-2

Front brake cutting solenoid
S03 DT-T 2 (If equipped) E9 G-2
Auto suspension solenoid 1
S04 DT-T 2 (If equipped) F9 H-2
Auto suspension solenoid 2
S05 DT-T 2 (If equipped) F9 H-1
SBS DT-T 2 Seat belt switch U2 F-1
SDE M 6 Side lamp switch (If equipped) N2 A-7
SF1 DT-T 12 Shift lever R9 B-9 B-2 H-9

(Green)
SF2 DT-T 2 Shift lever Q9
SIG HD30 31 Intermediate connector AJ7 F-6 H-4 J-7 J-5 B-3
SLG Terminal 1 Grounding C8 I-8
SLG Terminal 1 Grounding J2 I-2
SLL M 1 Side lamp (If equipped) J2 G-2
SLR M 1 Side lamp (If equipped) C7 J-9
S-NET MS3102A
14S 5 S-NET monitor T1 A-9
SP1 PACKARD 2 Engine speed sensor (Master) AJ8 A-1
SP2 PACKARD 2 Engine speed sensor (Backup) AJ8 A-1
SPA1 DT-T 4 Spare connector 1 C-6
SPA2 DT-T 12 Spare connector 2 C-5
SPA3 DT-T 6 Spare connector 3 F1
SPL YAZAKI 2 Speaker (Left) G9
SPR YAZAKI 2 Speaker (Right) F9
SR2 X 3 Steering speed sensor P1 F-9
SR3 X 2 Pitch angle sensor X7 B-1
SUFL DT-T 3 Suspension oil pressure sensor(FL) H1 H-1 K-5

(If equipped)
SUFR DT-T 3 Suspension oil pressure sensor(FR) B7 G-9 K-6
(If equipped)
SURL DT-T 3 Suspension oil pressure sensor(RL) L8 K-5 K-5
(If equipped)
SURR DT-T 3 Suspension oil pressure sensor(RR) J9 K-5 K-5
(If equipped)
T01 DT-T 2 Fuel level gauge sensor G9 I-9
T02 DT-T 6 Retarder oil temperature sensor H9 J-8
HD465-7, HD605-7 20-355

(10)
Address
Con- Type Num-
3-dimen-
T05 Terminal 1 Grounding I9 K-1
T1 Terminal 1 Grounding AC9 I-3
TEST One-pin 1 TEST switch V8 F-5

connector
TG One-pin 1 Tachograph S9
connector
TG2 One-pin 1 Tachograph S9
connector
TIMG PACKARD 3 Timing rail actuator AG9 D-1
TM2 HD30 21 Intermediate connector AD8 H-5 J-4
TM3 HD30 31 Intermediate connector AD8 H-5
TMF DT-T 2 Transmission oil filter sensor J3 I-9
TPR PACKARD 3 Timing rail pressure sensor AI6 C-1
TR 6 Brake lamp timer X7 E-1
VHM DT-T 8 Intermediate connector C2

(Black)
WFM M 6 Front wiper motor Q1 A-4
WFR Relay 6 Front wiper relay R1 A-3
WPS DT-T
(Black) 12 Wiper switch Q8 B-3
WSRL DT-T 2 Wheel speed sensor (RL) K1 B-9
WSRR DT-T 2 Wheel speed sensor (RR) K1 C-9
VHMS controller related
CAN1 DT-T 3 VHMS intermediate connector AU2 E-5
DLSW Terminal 1 Ground level download box AO1 A-7
EG4 DT-T 12 VHMS intermediate connector AV3 E-6
GDL DT-T 12 Ground level download box inter- AP4 A-6

mediate connector
GR1 Terminal 1 Ground level download box AP2 A-7
GR2 Terminal 1 Ground level download box AP2 A-7
HM-12 DT-T 3 Blow-by sensor AM6 B-4
HM-21A DT 2 Exhaust temperature sensor AN8 B-2
HM-21B DT 2 Exhaust temperature sensor AN7 B-2
HM-22A DT 2 Exhaust temperature sensor - amp AR8 J-2

intermediate connector
HM-22B DT 2 Exhaust temperature sensor - amp AQ7 J-2
HM-23A DT-T 3 VHMS - exhaust temperature amp AR8 J-2
VHMS - exhaust temperature amp
HM-23B DT-T 3 intermediate connector AQ7 J-2
HM-31 DT 2 Engine oil temperature sensor AN1 B-4
HM-35 DT 2 Ambient temperature sensor AM1 B-8
HM50 DT-T 3 Short connector AU2 H-8
HM55 DT-T 3 Short connector AQ6 I-8
20-355-1 HD465-7, HD605-7

(10)
Address
Con- Type Num-
3-dimen-
HM81 M 8 VHMS - Orbcomm controller inter- AT2 L-3
mediate connector
HM-2130 YAZAKI 2 Resistor AQ2 H-8
HM-2140 YAZAKI 2 Resistor AR2 H-8
HM-CN1 AMP070 20 VHMS controller AS8 I-8
HM-CN2A AMP070 18 VHMS controller AT7 J-8
HM-CN2B AMP070 12 VHMS controller AU7 J-8
HM-CN3A AMP070 18 VHMS controller AT8 J-8
HM-CN3B AMP070 12 VHMS controller AS8 K-8
HM-CN4A AMP070 14 VHMS controller AU7 K-8
HM-CN4B AMP070 10 VHMS controller AT8 L-8
LM1 Terminal 1 Ground level download box lamp

terminal AP3 B-7
LM2 Terminal 1 Ground level download box lamp AP3 B-7

terminal
ORB-A AMP070 14 Orbcomm controller AS2 K-2
ORB-B AMP070 10 Orbcomm controller AS2 L-2
PDL MS 5 Ground level download box PLM AP2 A-7

connector
PLM MS 5 PLM II download connector AQ6 K-4
PM1 MIC 21 PLM II intermediate connector AV3 F-7,

H-7
PM4 S 16 PLM II intermediate connector AU7 F-6,
H-6
PM11 MIC 21 VHMS intermediate connector AV6 E-5
Ambient temperature sensor
SPA1 DT-T 4 intermediate connector AO6 C-6
SPA2 DT-T 12 Ground level download box AO6 C5

VDL MS 5 Ground level download box VHMS AP3 A-7
connector
VHM DT-T 8 Blow-by, oil temperature sensor in- AM6 B-4
termediate connector
VHMS MS 5 VHMS download connector AT2 K-4
WAKE Terminal 1 Ground level download box AP2 A-7
HD465-7, HD605-7 20-355-2

(10)
ABS control related

Address
Connec- Type Num-
tor of ber Location 3-dimen- System diagram
sional
diagram ENG TM BK PLM MON VHMS ASR ABS
ABS M 6 ABS system switch O2 E-9 BK7
ABS1 MIC 17 ABS controller BR3
ABS1 DT-T 6 Joint connector BF9
ABS2 MIC 21 ABS controller BR3
ABS2 DT-T 8 Joint connector BD2
ABS3 DT-T 6 Joint connector BE2
ABS3A 040 20 ABS controller BR8
ABS3B 040 16 ABS controller BQ9
ABS4 040 12 ABS controller BR8
ABS5 DT 6 Joint connector BF3
ABS5A 040 20 ABS controller BR8
ABS6 DT-T 6 Joint connector BG8
ABS7 DT-T 6 Joint connector BH8
ABSFL DT-T 2 ABS valve AX9
ABSFR DT-T 2 ABS valve AX9
ABSRL DT-T 2 ABS valve BH7
ABSRR DT-T 2 ABS valve BF9
BPFL DT-T 3 Brake oil pressure AW9
BPFR DT-T 3 Brake oil pressure AX9
BPRL DT-T 3 Brake oil pressure BH8
BPRR DT-T 3 Brake oil pressure BG9
BRC3B 040 16 Retarder controller Y4 A-5 BO9
BRC4 040 12 Retarder controller Z4 J-9 C-1 A-5 D-1 H-1 BP9
BRC5A 040 20 Retarder controller Y1 A-4 BQ9
CHK Yazaki 6 System check switch BL8
CVF DT-T 2 ABS cut solenoid AZ8
CVR DT-T 2 ABS cut solenoid BG9
CVSF DT-T 3 ABS cut switch AY8
CVSR DT-T 3 ABS cut switch BH8
DA1 DT-T 2 Diode BE9
DPC2B AMP070 12 Machine monitor P1 C-1 A-6 F-1 P1
FOGF M 6 Fog lamp switch BM1
FOGM M 6 Fog lamp switch BK8
J06 HD30 31 Intermediate connector BD1
JABS DT-T 12 Intermediate connector BA9
RABS KES1 6 ABS cut relay BS7
RABS2 KES1 6 ABS cut valve relay BS7
S01F DT-T 3 Service brake switch BC1
S01M DT-T 3 Service brake switch AZ1
S02F DT-T 3 Secondary brake switch BC9
S02M DT-T 3 Secondary brake switch BC9
WSFL DT-T 2 Wheel speed sensor BC1
WSFR DT-T 2 Wheel speed sensor AY7
WSRL2 DT-T 2 Wheel speed sensor BG9
WSRR2 DT-T 2 Wheel speed sensor BF9
20-355-3 HD465-7, HD605-7

(12)
TROUBLESHOOTING CONNECTOR ARRANGMENT LOCATION
CONNECTOR ARRANGEMENT LOCATION
20-356 HD465-7, HD605-7

(5)
HD465-7, HD605-7 20-357

(5)
20-358 HD465-7, HD605-7

(1)
HD465-7, HD605-7 20-359

(1)
20-360 HD465-7, HD605-7

(1)
HD465-7, HD605-7 20-361

(1)
VHMS control related

(1/2)
20-362 HD465-7, HD605-7

(2)
(2/2)
HD465-7, HD605-7 20-363

(2)
ABS control related

(1/2)
20-364 HD465-7, HD605-7

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HD465-7, HD605-7 20-365

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(2/2)
20-366 HD465-7, HD605-7

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HD465-7, HD605-7 20-367

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TROUBLESHOOTING OF ENGINE
CONTROLLER SYSTEM
(ENG MODE)
Electrical system diagram related engine control ...................................................................................... 20-404

Information in troubleshooting table ............................................................................................................ 20-406
[C111KT] Abnormality in engine controller memory ............................................................................ 20-408
[C112LK] Abnormality in timing rail actuator ....................................................................................... 20-408
[C113KZ] Abnormal current in timing rail actuator system .................................................................. 20-409
[C115KZ] Abnormality in engine speed sensor 2 systems .................................................................. 20-410
[C116KX] Abnormally high level in timing rail pressure sensor system ............................................... 20-412
[C117KX] Abnormally low level in timing rail pressure sensor system ................................................ 20-413
[C118KX] Abnormally high level in fuel pump pressure sensor system ............................................... 20-414
[C119KX] Abnormally low level in fuel pump pressure sensor system ................................................ 20-415
[C121LC] Abnormality in engine speed sensor 1 systems .................................................................. 20-415
[C122KX] Abnormally high level in boost pressure sensor system ...................................................... 20-416
[C123KX] Abnormally low level in boost pressure sensor system ....................................................... 20-417
[C131KX] Abnormally high level in throttle sensor system .................................................................. 20-418
[C132KX] Abnormally low level in throttle sensor system .................................................................... 20-420
[C135KX] Abnormally high level in engine oil pressure sensor system ............................................... 20-421
[C141KX] Abnormally low level in engine oil pressure sensor system ................................................ 20-422
[C143ZG] Lowering of engine oil pressure ........................................................................................... 20-422
[C144KX] Abnormally high level in engine coolant temperature sensor system .................................. 20-423
[C145KX] Abnormally low level in engine coolant temperature sensor system ................................... 20-424
[C148KX] Abnormality in FM throttle: Out of input signal range .......................................................... 20-425
[C151NS] Rise of engine coolant temperature ..................................................................................... 20-426
[C153KX] Abnormally high level in air intake temperature sensor system ........................................... 20-427
[C154KX] Abnormally low level in air intake temperature sensor system ............................................ 20-428
[C221KX] Abnormally high level in atmospheric pressure sensor system ........................................... 20-429
[C222KX] Abnormally low level in atmospheric pressure sensor system ............................................ 20-430
[C234NI] Over-speed .......................................................................................................................... 20-430
[C254KZ] Abnormal voltage of fuel shut-off valve................................................................................. 20-431
[C259FS] Abnormality in fuel shut-off valve ......................................................................................... 20-432
[C261NS] Abnormal rise of fuel temperature ....................................................................................... 20-432
[C263KX] Abnormally high level in fuel temperature sensor system ................................................... 20-433
[C265KX] Abnormally low level in fuel temperature sensor system ..................................................... 20-434
[C316KZ] Abnormal current of fuel pump actuator .............................................................................. 20-435
[C318LK] Abnormality in fuel pump actuator ....................................................................................... 20-436
[C346KT] Abnormality in power-down unit of engine controller ........................................................... 20-437
[C423L6] Abnormality in in-range of timing rail pressure sensor system ............................................ 20-439
[C431L4] Abnormality in idle validation switch system: *See separate list (L4)
(Both signal voltages of 2 systems are sensed) ................................................................. 20-441
[C432L5] Error in idle validation process ( *See separate list (L5))...................................................... 20-443
[C441KX] Abnormally low level in battery voltage system .................................................................. 20-445
[C442KG] Abnormally high level in battery voltage system .................................................................. 20-445
[C451KX] Abnormally high level in fuel rail pressure sensor system ................................................... 20-446
[C452KX] Abnormally low level in fuel rail pressure sensor system .................................................... 20-447
[C455KZ] Abnormal current of fuel rail actuator .................................................................................. 20-448
HD465-7, HD605-7 20-401

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[C467LK] Abnormality in timing rail actuator control ........................................................................... 20-449
[C468LK] Abnormality in fuel rail actuator control ................................................................................ 20-449
[C514LK] Abnormality in fuel rail actuator .......................................................................................... 20-450
[C551L4] Abnormality in idle validation switch system: *See separate list (L4)
(Either signal voltage of 2 systems is not sensed) ............................................................... 20-451
[C554L6] Abnormality in in-range of fuel rail pressure sensor system ................................................ 20-453
ENG-1 Engine does not start............................................................................................................ 20-455
ENG-2 Failure in preheating ............................................................................................................. 20-459
a) Engine is not preheated................................................................................................... 20-459
b) Preheating is actuated even under non-actuation conditions for preheating................... 20-462
ENG-3 AISS function does not work normally .................................................................................. 20-464
a) When AISS switch is set in AUTO, LOW SPEED control is selected.............................. 20-464
b) When AISS switch is set in LOW SPEED, AUTO control is selected.............................. 20-465
20-402 HD465-7, HD605-7

(10)
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED ENGINE CONTROL
ELECTRICAL SYSTEM DIAGRAM RELATED ENGINE CONTROL

Engine serial No. : 310169 310414
20-404 HD465-7, HD605-7

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HD465-7, HD605-7 20-405

(2)
Engine serial No. : 310415 310798
20-405-1 HD465-7, HD605-7

(8)
HD465-7, HD605-7 20-405-2

(8)
Engine serial No. : 310799 and up
20-405-3 HD465-7, HD605-7

(8)
HD465-7, HD605-7 20-405-4

(8)
TROUBLESHOOTING INFORMATION IN TROUBLESHOOTING TABLE
INFORMATION IN TROUBLESHOOTING TABLE

a The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before carrying out troubleshooting, understand that information fully.
Action code Failure code Controller code
Display on Display on Display on Trouble Trouble in machine
panel panel panel
Contents of trouble Contents of trouble detected by monitor panel or controller
Action of controller
Action taken by controller to protect system or devices when monitor panel or controller detects trouble
or monitor panel
Problem that
Problem that appears on machine as result of action taken by monitor panel or controller (shown above)
appears on machine
Related information Information related to detected trouble or troubleshooting
Cause Standard value in normal state/Remarks on troubleshooting

<Contents of description>
Standard value in normal state to judge possible causes
Remarks on judgment
1
<Troubles in harness>
Disconnection
Connector is connected imperfectly or harness is broken.
Ground fault
Harness which is not connected to chassis ground circuit is in con-
2 tact with chassis ground circuit.
Short circuit with power source (Hot short)
Harness which is not connected to power source (24 V) circuit is in
contact with power source (24 V) circuit.
Short circuit
Independent harnesses are in contact with each other abnormally.
Possible causes Possible causes of trouble
and standard value (Given numbers are refer-
3 <Precautions for troubleshooting>
in normal state ence numbers, which do not 1) Method of indicating connector No. and handling of T-adapter
indicate priority) Insert or connect T-adapter as explained below for troubleshooting,
unless otherwise specified.
If connector No. has no marks of "male" and "female", disconnect
connector and insert T-adapters in both male side and female
side.
4 If connector No. has marks of "male" and "female", disconnect
connector and connect T-adapter to only male side or female side.
2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative () lead of tester as ex-
plained below for troubleshooting, unless otherwise specified.
Connect positive (+) lead to pin No. or harness entered on front
side.
5
Connect negative () lead to pin No. or harness entered on rear
side.
20-406 HD465-7, HD605-7

(10)
Related electrical circuit diagram
Part of electric circuit diagram related to trouble

Connector No.: Indicates (Model Number of pins) and (Color).
Arrows ( ): Indicate rough location of connector in machine.
PHENOMENON CODE TABLE

a Regarding phenomenon code provided with instruction "Refer to table", check it against table below.
Phenomenon Phenomenon
code Contents code Contents
Fill signals at two or more channels which are not set as combi-
KA Disconnection in wiring L0 nation are turned ON at the same time.
KB Short circuit L1 Fill signal is ON when command current to ECMV is OFF.
Source voltage reduction/
KK input L2 Fuel pressure is above maxim specified value.
Type select signal incon-

KQ sistency L3 Object part is uncontrollable.
KR Defective communication L4 ON and OFF signals at two systems are inconsistent.

Engine rotation signal, terminal C signal, oil pressure switch
KT Abnormality in controller L6 signal, coolant temperature sensor signal, etc. are inconsistent
with operation state or stop state.
KX Outside input signal range L8 Analog signals in two systems are inconsistent.
Short circuit with power
KY source (Hot short) LC rpm signals in two systems are inconsistent.
Disconnection or short cir-

KZ cuit LD Switch is pressed for usually unthinkable long time.
MA Malfunction LH Fill signal is OFF when command current to ECMV is ON.

MB Performance reduction
MW Sliding
NS Overheat
ZG Oil pressure reduction
ZK Coolant level reduction
HD465-7, HD605-7 20-407

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TROUBLESHOOTING [C111KT], [C112LK]
[C111KT] ABNORMALITY IN ENGINE CONTROLLER MEMORY
Action code Failure code Controller code Abnormality in engine controller memory
Trouble
E03 C111KT ENG (Engine controller system)
Contents of trouble Memory in controller has trouble or processor in controller has communication trouble.
Action of controller Flashes warning lamp and turns on alarm buzzer.
Problem that
Engine cannot be started.
appears on machine
Related information Method of reproducing failure code: Turn starting switch ON.

Reset according to following procedure. If failure code E is displayed
Possible causes
at this time, engine controller is defective.
and standard value
in normal state 1 Defective engine controller 1) Keep starting switch at OFF position for 5 seconds.
2) Run engine at low idle.
3) Check failure code.
[C112LK] ABNORMALITY IN TIMING RAIL ACTUATOR
Action code Failure code Controller code Abnormality in timing rail actuator
Trouble
E03 C112LK ENG (Engine controller system)
Displayed fuel value of timing rail is excessively different from actual timing fuel.
Contents of trouble Judgment value (for reference):
Error is above 400 mm3/st or below 750 mm3/st (When coolant temperature is below 0C).
Flashes warning lamp and turns on alarm buzzer.
Limits engine speed to 1,500 rpm.
Problem that
Engine speed lowers.
appears on machine
Related information Method of reproducing failure code: Start engine.

Check displayed failure codes. If code related to engine controller is
1 Defective related systems
displayed, carry out troubleshooting for it first.
Clogging, looseness, break-
Check fuel filter/piping directly for clogging, looseness, breakage, and
2 age, or leakage of fuel filter/
Possible causes leakage.
piping
and standard value
3 Defective timing rail actuator Check timing rail actuator directly for defective operation.
in normal state
Clogging of timing rail actua-
4 Check timing rail actuator screen directly for clogging.
tor screen
5 Breakage of injector O-ring Check injector O-ring directly for breakage.
If causes 1 5 are not detected, engine controller may be defective.
6 Defective engine controller
(Since trouble is in system, troubleshooting cannot be carried out.)
20-408 HD465-7, HD605-7

(10)
TROUBLESHOOTING [C113KZ]
[C113KZ] ABNORMAL CURRENT IN TIMING RAIL ACTUATOR SYSTEM
Action code Failure code Controller code Abnormal current in timing rail actuator system
Trouble
E03 C113KZ ENG (Engine controller system)
Current in timing rail actuator is out of normal range.
Contents of trouble
Normal range (for reference): 0.40 0.35 A (When engine is stopped)
Problem that Engine output lowers.
appears on machine Exhaust gas becomes white.
Special cable (795-799-5460) is necessary for troubleshooting for timing rail actuator.
Related information
Method of reproducing failure code: Turn starting switch ON (or start engine).

aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective timing rail actuator TIMG (male) Resistance
1
(Internal trouble)
Between (A) (C) 79z
Between (A), (C) chassis ground Min. 100 kz
Disconnection in wiring har- without turning starting switch ON.
ness
Wiring harness between ECMA (female) (1)
2 (Disconnection in wiring or Resistance Max. 10 z
TIMG (female) (A)
defective contact in connec-
tor) Wiring harness between ECMA (female) (20)
Resistance Max. 10 z
TIMG (female) (C)
Possible causes
and standard value aPrepare with starting switch OFF, then carry out troubleshooting
in normal state without turning starting switch ON
Short circuit in wiring har- Wiring harness between ECMA (female) (1)
ness TIMG (female) (A) with wiring harness around Resistance Min. 1 M z
3
(with another wiring har- it
ness) Wiring harness between ECMA (female) (20)
TIMG (female) (C) with wiring harness around Resistance Min. 1 M z
it
ECMA (female) Resistance
Between (1) (20) 79z
Wiring harness between (1), (20)
Min. 1 M z
wiring harness around it
Circuit diagram related to timing rail actuator
HD465-7, HD605-7 20-409

(11)
[C115KZ] ABNORMALITY IN ENGINE SPEED SENSOR 2 SYSTEMS
Action code Failure code Controller code Abnormality in engine speed sensor 2 systems
Trouble
Contents of trouble Signal is not input to either of engine speed sensor circuit 2 systems.
Outputs speed signal of 0 rpm.
Problem that
Engine stops.
appears on machine
Inputting from engine speed sensor (rpm) can be checked in monitoring mode.
(Code 01001, 01002: Engine speed)
Related information
Special cable (795-799-5520) is necessary for troubleshooting for engine speed sensor.
Method of reproducing failure code: Start engine.

without turning starting switch ON
SP (male) Resistance
Defective engine speed sen-
1 sor Between (2) (1) and (3) (4) 1 2 kz
(Internal trouble) Between (2) (3) Max. 10 z
Between (1) (4) Max. 10 z
Between (2), (3) chassis ground Min. 10 Mz
Damage of engine speed
2 Check engine speed sensor directly.
sensor
Disconnection in wiring har- Resistance Max. 10 z
SP (female) (2)
ness
SP (female) (1)
Possible causes SP (female) (3)
and standard value Wiring harness between ECMA (female) (38)
in normal state Resistance Max. 10 z
SP (female) (4)
Resistance Min. 1 Mz
Short circuit in wiring har- SP (female) (2) with wiring harness around it
ness Wiring harness between ECMA (female) (28)
4 Resistance Min. 1 Mz
(with another wiring har- SP (female) (1) with wiring harness around it
SP (female) (3) with wiring harness around it
SP (female) (4) with wiring harness around it
aPrepare with starting switch OFF, then start engine and carry out
troubleshooting.
5 Defective engine controller Between (27) (28) 1 2 kz
Between (37) (38) 1 2 kz
20-410 HD465-7, HD605-7

(10)
Circuit diagram related to engine speed sensor
HD465-7, HD605-7 20-411

(8)
TROUBLESHOOTING [C116KX]
[C116KX] ABNORMALLY HIGH LEVEL IN TIMING RAIL PRESSURE SENSOR SYSTEM
Action code Failure code Controller code Abnormally high level in timing rail pressure sensor system
Trouble
E03 C116KX ENG (Engine controller system)
Contents of trouble Signal voltage of timing rail pressure sensor circuit is above 4.78 V.
Action of controller Opens and controls timing rail.
Problem that Engine makes abnormal combustion sound or discharges white smoke, then its speed is set to
appears on machine 1,500 rpm.
Special cable (795-799-5480) is necessary for troubleshooting for timing rail pressure sensor.
Related information

aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective timing rail pres-
1 sure sensor TPR Voltage
(Internal trouble) Between (A) (B) 4.75 5.25 V
Between (C) (B) 0.42 0.58 V
Disconnection in wiring har-
ness Resistance Max. 10 z
TPR (female) (A)
2 (Disconnection in wiring or
defective contact in connec- Wiring harness between ECMA (female) (18)
tor) TPR (female) (B)
Possible causes Wiring harness between ECMA (female) (33)
and standard value TPR (female) (C)
in normal state aPrepare with starting switch OFF, then carry out troubleshooting
ness TPR (female) (A) with wiring harness around it
3
(with another wiring har- Wiring harness between ECMA (female) (18)
ness) Resistance Min. 1 Mz
TPR (female) (B) with wiring harness around it
TPR (female) (C) with wiring harness around it
4 Defective engine controller ECMA Voltage
Between (5) (18) 4.75 5.25 V
Between (33) (18) 0.42 0.58 V
Circuit diagram related to timing rail pressure
20-412 HD465-7, HD605-7

(11)
[C117KX] ABNORMALLY LOW LEVEL IN TIMING RAIL PRESSURE SENSOR SYSTEM
Action code Failure code Controller code Abnormally low level in timing rail pressure sensor system
Trouble
Contents of trouble Signal voltage of timing rail pressure sensor circuit is below 0.30 V
Action of controller Opens and controls timing rail.
Problem that Engine makes abnormal combustion sound or discharges white smoke, then its speed is set to
appears on machine 1,500 rpm.
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard value
in normal state Carry out troubleshooting for failure code [C116KX].
HD465-7, HD605-7 20-413

(10)
[C118KX] ABNORMALLY HIGH LEVEL IN FUEL PUMP PRESSURE SENSOR SYSTEM
Action code Failure code Controller code Abnormally high level in fuel pump pressure sensor system
Trouble
Contents of trouble Signal voltage of fuel pump pressure sensor circuit is above 4.78 V.
Opens and controls fuel pump.
Problem that
appears on machine
Special cable (795-799-5480) is necessary for troubleshooting for fuel pump pressure sensor.
Related information

Defective fuel pump pres-
1 sure sensor PMPR (male) Voltage
Between (C) (B) 0.42 0.58 V
PMPR (female) (A)
PMPR (female) (B)
tor)
Possible causes PMPR (female) (C)
in normal state without turning starting switch ON.
Short circuit in wiring har- PMPR (female) (A) with wiring harness around Resistance Min. 1 Mz
it
ness
3 Wiring harness between ECMA (female) (18)
(with another wiring har-
ness) PMPR (female) (B) with wiring harness around Resistance Min. 1 Mz
it
PMPR (female) (C) with wiring harness around Resistance Min. 1 Mz
it
4 Defective engine controller ECMA (female) Resistance
Between (5) (18) 4.75 5.25 V
Between (32) (18) 0.42 0.58 V
Circuit diagram related to fuel pump pressure sensor
20-414 HD465-7, HD605-7

(11)
TROUBLESHOOTING [C119KX], [C121LC]
[C119KX] ABNORMALLY LOW LEVEL IN FUEL PUMP PRESSURE SENSOR SYSTEM
Action code Failure code Controller code Abnormally low level in fuel pump pressure sensor system
Trouble
Contents of trouble Signal voltage of fuel pump pressure sensor circuit is below 0.30 V.
Opens and controls fuel pump.
Problem that
appears on machine

and standard value
[C121LC] ABNORMALITY IN ENGINE SPEED SENSOR 1 SYSTEMS
Action code Failure code Controller code Abnormality in engine speed sensor 1 systems
Trouble
E01 C121LC ENG (Engine controller system)
Contents of trouble Signal is not input to both of engine speed sensor circuit 2 systems.
Problem that
appears on machine
Inputting from engine speed sensor (rpm) can be checked in monitoring mode.
Related information (Code 01001: Engine speed)

and standard value
in normal state Carry out troubleshooting for failure code [C115KZ].
HD465-7, HD605-7 20-415

(10)
[C122KX] ABNORMALLY HIGH LEVEL IN BOOST PRESSURE SENSOR SYSTEM
Action code Failure code Controller code Abnormally high level in boost pressure sensor system
Trouble
Contents of trouble Signal voltage of boost pressure sensor circuit is above 4.72 V.
Problem that When machine is accelerated suddenly, exhaust gas color is bad.
appears on machine Engine output rises.
Special cable (795-799-5480) is necessary for troubleshooting for boost pressure sensor.
Related information

Defective boost pressure
1 sensor IMPR (male) Voltage
Between (C) (B) 0.42 0.58 V
IMPR (female) (A)
IMPR (female) (B)
tor)
Possible causes IMPR (female) (C)
Short circuit in wiring har- IMPR (female) (A) with wiring harness around Resistance Min. 1 Mz
it
ness
ness) IMPR (female) (B) with wiring harness around Resistance Min. 1 Mz
it
IMPR (female) (C) with wiring harness around Resistance Min. 1 Mz
it
Between (6) (17) 4.75 5.25 V
Between (35) (17) 0.42 0.58 V
Circuit diagram related to boost pressure sensor
20-416 HD465-7, HD605-7

(11)
[C123KX] ABNORMALLY LOW LEVEL IN BOOST PRESSURE SENSOR SYSTEM
Action code Failure code Controller code Abnormally low level in boost pressure sensor system
Trouble
Contents of trouble Signal voltage of boost pressure sensor circuit is below 0.30 V.
Problem that
Engine output lowers.
appears on machine

and standard value
HD465-7, HD605-7 20-417

(10)
[C131KX] ABNORMALLY HIGH LEVEL IN THROTTLE SENSOR SYSTEM
Action code Failure code Controller code Abnormally high level in throttle sensor system
Trouble
Contents of trouble Signal voltage of throttle sensor (throttle potentiometer) circuit is above 4.80 V.
Keeps engine speed at constant level.
Problem that
Engine output and speed rise suddenly.
appears on machine
Inputting from deceleration potentiometer to steering controller (Voltage) can be checked in monitoring
mode.
Related information
(Code 31701: throttle potentiometer voltage)
Method of reproducing failure code: Turn starting switch ON.

Defective throttle potentiom- AS1 (male) Resistance
1 eter
Between (3) (1) 4.0 6.0 kz
(Internal trouble)
Between (3) (2) 0.25 7.0 kz
Between (2) (1) 0.25 7.0 kz
Wiring harness between ECMB (female) (26)
AS1 (female) (3)
defective contact in connec- Resistance Max. 10 z
AS1 (female) (1)
tor)
Possible causes Wiring harness between ECMB (female) (29)
and standard value Resistance Max. 10 z
AS1 (female) (2)
Short circuit of wiring harness between ECMB
Short circuit in wiring har- (female) (26) AS1 (female) (3) with wiring Resistance Min. 1 Mz
harness around it
ness
3 Short circuit of wiring harness between ECMB
ness) (female) (11) AS1 (female) (1) with wiring Resistance Min. 1 Mz
harness around it
Short circuit of wiring harness between ECMB
(female) (29) AS1 (female) (2) with wiring Resistance Min. 1 Mz
harness around it
ECMB Voltage
Between (29) (11) 0.30 4.80 V
20-418 HD465-7, HD605-7

(10)
Circuit diagram related to deceleration potentiometer
HD465-7, HD605-7 20-419

(1)
[C132KX] ABNORMALLY LOW LEVEL IN THROTTLE SENSOR SYSTEM
Action code Failure code Controller code Abnormally low level in throttle sensor system
Trouble
Contents of trouble Signal voltage of throttle sensor (throttle potentiometer) circuit is below 0.30 V.
Keeps engine speed at constant level.
Problem that
Engine speed and output lower suddenly.
appears on machine
Inputting from deceleration potentiometer to steering controller (Voltage) can be checked in monitoring
mode.
Related information
(Code 31701: throttle potentiometer voltage)

and standard value
20-420 HD465-7, HD605-7

(10)
[C135KX] ABNORMALLY HIGH LEVEL IN ENGINE OIL PRESSURE SENSOR SYSTEM
Action code Failure code Controller code Abnormally high level in engine oil pressure sensor system
Trouble
Contents of trouble Signal voltage of engine oil pressure sensor circuit is above 4.88 V.
Problem that
appears on machine
Special cable (795-799-5470) is necessary for troubleshooting for engine oil pressure sensor.
Related information

Defective engine oil pres-
1 sure sensor OLPR Voltage
Between (C) (B) 0.42 0.58 V
OLPR (female) (A)
tor) OLPR (female) (B)
Possible causes OLPR (female) (C)
Short circuit of wiring harness between ECMA
Short circuit in wiring har- (female) (6) OLPR (female) (A) with wiring Resistance Min. 1 Mz
harness around it
ness
3 Short circuit of wiring harness between ECMA
ness) (female) (17) OLPR (female) (B) with wiring Resistance Min. 1 Mz
harness around it
Short circuit of wiring harness between ECMA
(female) (24) OLPR (female) (C) with wiring Resistance Min. 1 Mz
harness around it
Between (6) (17) 4.75 5.25 V
Between (24) (17) 0.42 0.58 V
Circuit diagram related to engine oil pressure sensor
HD465-7, HD605-7 20-421

(10)
TROUBLESHOOTING [C141KX], [C143ZG]
[C141KX] ABNORMALLY LOW LEVEL IN ENGINE OIL PRESSURE SENSOR SYSTEM
Action code Failure code Controller code Abnormally low level in engine oil pressure sensor system
Trouble
Contents of trouble Signal voltage of engine oil pressure sensor circuit is below 0.31 V.
Problem that
appears on machine

and standard value
[C143ZG] LOWERING OF ENGINE OIL PRESSURE
Action code Failure code Controller code Lowering of engine oil pressure
Trouble
E03 C143ZG ENG (Engine controller system)
Engine oil pressure sensor detected pressure lower than pressure set in controller.
Criterion (for reference): Max. 0.05 MPa {0.5 kg/cm2} at 600 rpm
Max. 0.09 MPa {0.9 kg/cm2} at 1,000 rpm
Contents of trouble
Action of controller Limits fuel injection rate to 50% after 10 seconds.
Problem that
appears on machine

Possible causes 1 Defective related systems
and standard value
in normal state Defective engine oil pres-
2 Carry out troubleshooting for failure codes [C135KX] and [C141KX].
sure sensor system
3 Defective engine See Shop Manual for engine (170-3 Series).
20-422 HD465-7, HD605-7

(10)
[C144KX] ABNORMALLY HIGH LEVEL IN ENGINE COOLANT TEMPERATURE

SENSOR SYSTEM
Action code Failure code Controller code Abnormally high level in engine coolant temperature sensor system
Trouble
Contents of trouble Signal voltage of engine coolant temperature sensor circuit is above 4.95 V.
Problem that
appears on machine
Special cable (795-799-5530) is necessary for troubleshooting for engine coolant temperature sensor.
Related information

Defective engine coolant without turning starting switch ON.
1 temperature sensor
CLTP Resistance
(Internal trouble)
Between (A) (B) 600 36 kz
ness
2 (Disconnection in wiring or Wiring harness between ECMA (female) (22) Resistance Max. 10 z
CLTP (female) (A)
Possible causes Resistance Max. 10 z
CLTP (female) (B)
and standard value
in normal state
Short circuit in wiring har- Short circuit of wiring harness between ECMA
ness (female) (22) CLTP (female) (A) with wiring Resistance Min. 1 Mz
3
(with another wiring har- harness around it
ness) Short circuit of wiring harness between ECMA
(female) (17) CLTP (female) (B) with wiring Resistance Min. 1 Mz
harness around it
Between (22) (17) 600 36 kz
Circuit diagram related to engine coolant temperature sensor
HD465-7, HD605-7 20-423

(10)
[C145KX] ABNORMALLY LOW LEVEL IN ENGINE COOLANT TEMPERATURE SENSOR

SYSTEM
Action code Failure code Controller code Abnormally low level in engine coolant temperature sensor system
Trouble
Contents of trouble Signal voltage of engine coolant temperature sensor circuit is below 0.21 V.
Problem that
appears on machine

and standard value
20-424 HD465-7, HD605-7

(10)
[C148KX] ABNORMALITY IN FM THROTTLE: OUT OF INPUT SIGNAL RANGE

Trouble Abnormality in FM throttle: Out of input signal range
E03 C148KX ENG
Contents of trouble The frequency of the FM throttle is below 150 Hz or above 400 Hz.
The throttle sensor signal is conformed to the idle validation switch (In idle: 0%, Off idle: 35%).
Problem that
The engine speed is kept at low idle or 1,500 rpm (Throttle: 35%).
appears on machine
Related information

1) Turn the starting switch OFF.
Disconnection in wiring har- 2) Disconnect connector ECM.
ness 3) Connect T-adapter.
1
(Disconnection or defective
contact) Resistance Max. 10 z
ATC3A (female) (5)
2) Disconnect connectors ECMB and ATC3A.
Ground fault in wiring har- 3) Connect T-adapter.
2
ness Wiring harness between Resistance between ECMB
ECMB (female) (17) (female) (17), ATC3A (fe- Min. 1 Mz
Possible causes
ATC3A (female) (5) male) (5) chassis ground
and standard value
in normal state 1) Turn the starting switch OFF.
2) Disconnect connector ATC3A.
3) Insert T-adapter.
Transmission controller de- 4) Connect the connector.
3
fective 5) Turn the starting switch ON.
Between ATC3A (male) (5) chassis
Frequency 170 380Hz
ground
1) Connect all the connectors.
2) Turn the starting switch ON.
4 Engine controller defective Check that the failure code disappears.
aIf the failure code does not disappear, replace the engine control-
ler.
Circuit diagram related to engine abnormality in FM throttle
HD465-7, HD605-7 20-425

(10)
TROUBLESHOOTING [C151NS]
[C151NS] RISE OF ENGINE COOLANT TEMPERATURE
Action code Failure code Controller code Rise of engine coolant temperature
Trouble
E02 C151NS ENG (Engine controller system)
Engine coolant temperature sensor detected temperature higher than temperature set in controller.
Contents of trouble
Criterion (for reference): Min. 105C
Action of controller Limits fuel injection rate to 50% after 10 seconds.
Problem that
appears on machine

and standard value
in normal state Defective engine coolant
temperature sensor system
20-426 HD465-7, HD605-7

(10)
[C153KX] ABNORMALLY HIGH LEVEL IN AIR INTAKE TEMPERATURE SENSOR

SYSTEM
Action code Failure code Controller code Abnormally high level in air intake temperature sensor system
Trouble
Contents of trouble Signal voltage of air intake temperature sensor circuit is above 4.88 V.
Problem that
appears on machine
Special cable (795-799-5540) is necessary for troubleshooting for air intake temperature sensor.
Related information

Defective air intake temper- without turning starting switch ON.
1 ature sensor
IMTP (female) Resistance
(Internal trouble)
Between (A) (B) 36 600 z
ness
IMTP (female) (A)
IMTP (female) (B)
and standard value
in normal state
ness IMTP (female) (A) with wiring harness around Resistance Min. 1 Mz
3
IMTP (female) (B) with wiring harness around Resistance Min. 1 Mz
it
Between (23) (17) 36 600 z
Circuit diagram related to air intake temperature sensor
HD465-7, HD605-7 20-427

(10)
[C154KX] ABNORMALLY LOW LEVEL IN AIR INTAKE TEMPERATURE SENSOR

SYSTEM
Action code Failure code Controller code Abnormally low level in air intake temperature sensor system
Trouble
Contents of trouble Signal voltage of air intake temperature sensor circuit is below 0.08 V.
Problem that
appears on machine

and standard value
20-428 HD465-7, HD605-7

(10)
[C221KX] ABNORMALLY HIGH LEVEL IN ATMOSPHERIC PRESSURE SENSOR

SYSTEM)
Action code Failure code Controller code Abnormally high level in atmospheric pressure sensor system
Trouble
Contents of trouble Signal voltage of atmospheric pressure sensor circuit is above 4.78 V
Problem that
appears on machine
Special cable (795-799-5460) is necessary for troubleshooting for atmospheric pressure sensor.
Related information

carry out troubleshooting
Defective atmospheric pres-
1 sure sensor AAPR Voltage
Between (C) (B) 0.42 0.58 V
AAPR (female) (A)
tor) AAPR (female) (B)
Possible causes AAPR (female) (C)
Short circuit in wiring har- AAPR (female) (A) with wiring harness around Resistance Min. 1 Mz
it
ness
ness) AAPR (female) (B) with wiring harness around Resistance Min. 1 Mz
it
AAPR (female) (C) with wiring harness around Resistance Min. 1 Mz
it
Between (6) (17) 4.75 5.25 V
Between (34) (17) 0.42 0.58 V
Circuit diagram related to atmospheric pressure sensor
HD465-7, HD605-7 20-429

(10)
TROUBLESHOOTING [C222KX] , [C234NI]
[C222KX] ABNORMALLY LOW LEVEL IN ATMOSPHERIC PRESSURE SENSOR

SYSTEM
Action code Failure code Controller code Abnormally low level in atmospheric pressure sensor system
Trouble
Contents of trouble Signal voltage of atmospheric pressure sensor circuit is below 0.20 V.
Problem that
appears on machine

and standard value
[C234NI] OVER-SPEED
Action code Failure code Controller code Over-speed

Trouble
E02 C234NI ENG (Engine controller system)
Engine speed sensor detected speed higher than speed set in controller.
Contents of trouble
Criterion (for reference): Min. 2,400 rpm
Action of controller Closes fuel rail actuator fully (Cuts out fuel).
Problem that
appears on machine

Possible causes
and standard value 1 Defective related systems
in normal state
20-430 HD465-7, HD605-7

(10)
[C254KZ] ABNORMAL VOLTAGE OF FUEL SHUT-OFF VALVE
Action code Failure code Controller code Abnormal voltage of fuel shut-off valve
Trouble
Contents of trouble Voltage (Resistance) of fuel shut-off valve circuit is above 6.0 V (below 20 z).
Action of controller Turns off power for fuel shut-off valve.
Problem that
Engine stops.
appears on machine

Defective fuel shut-off valve FSO (Valve side) Resistance
1
(Internal trouble)
Between (+) () 23 40 z
Between (+) chassis ground 100 kz
ness
FSO (wiring harness side) (+)
Possible causes tor) Wiring harness between FSO (wiring harness
and standard value side) () chassis ground
ness FSO (wiring harness side) (+) with wiring har- Resistance Min. 1 Mz
3
(with another wiring harness around it
ness) Wiring harness between FSO (wiring harness
side) () chassis ground with wiring harness Resistance Min. 1 Mz
around it
ECMA Resistance
Between (30) chassis ground 23 40 z
Circuit diagram related to fuel shut-off valve
HD465-7, HD605-7 20-431

(10)
TROUBLESHOOTING [C259FS], [C261NS]
[C259FS] ABNORMALITY IN FUEL SHUT-OFF VALVE
Action code Failure code Controller code Abnormality in fuel shut-off valve
Trouble
E03 C259FS ENG (Engine controller system)
Contents of trouble Fuel shut-off valve cannot be closed (Engine does not stop when electric power is turned off).
Turns off power for fuel shut-off valve.
Problem that
Engine cannot be stopped.
appears on machine

2 Trouble in fuel shut-off valve Check inside of fuel shut-off valve directly.
Possible causes
and standard value Clogging, looseness, break-
in normal state 3 age, or leakage of fuel filter/
leakage.
piping
4 Trouble in injector Check inside of injector directly.
[C261NS] ABNORMAL RISE OF FUEL TEMPERATURE
Action code Failure code Controller code Abnormal rise of fuel temperature
Trouble
E02 C261NS ENG (Engine controller system)
Fuel temperature sensor detected temperature lower than temperature set in controller.
Contents of trouble
Criterion (for reference): Min. 76C
Action of controller Limits engine speed to 800 rpm after 30 seconds.
Problem that
appears on machine

and standard value
in normal state Defective fuel temperature
sensor system
20-432 HD465-7, HD605-7

(10)
[C263KX] ABNORMALLY HIGH LEVEL IN FUEL TEMPERATURE SENSOR SYSTEM
Action code Failure code Controller code Abnormally high level in fuel temperature sensor system
Trouble
Contents of trouble Signal voltage of fuel temperature sensor circuit is above 4.95 V.
Problem that
appears on machine
Special cable (795-799-5530) is necessary for troubleshooting for fuel temperature sensor.
Related information

Defective fuel temperature without turning starting switch ON.
1 sensor
FLTP (female) Resistance
(Internal trouble)
Between (A) (B) 600 36 kz
ness
FLTP (female) (A)
FLTP (female) (B)
and standard value
in normal state
ness FLTP (female) (A) with wiring harness around Resistance Min. 1 Mz
3
FLTP (female) (B) with wiring harness around Resistance Min. 1 Mz
it
Between (26) (17) 600 36 kz
Circuit diagram related to fuel temperature sensor
HD465-7, HD605-7 20-433

(10)
[C265KX] ABNORMALLY LOW LEVEL IN FUEL TEMPERATURE SENSOR SYSTEM
Action code Failure code Controller code Abnormally low level in fuel temperature sensor system
Trouble
Contents of trouble Signal voltage of fuel temperature sensor circuit is below 0.21 V.
Problem that
appears on machine

and standard value
20-434 HD465-7, HD605-7

(10)
[C316KZ] ABNORMAL CURRENT OF FUEL PUMP ACTUATOR
Action code Failure code Controller code Abnormal current of fuel pump actuator
Trouble
Current of fuel pump actuator circuit is out of normal range.
Contents of trouble
Problem that
appears on machine
Special cable (795-799-5470) is necessary for troubleshooting for fuel pump actuator.
Related information

Defective fuel pump actuator PUMP (male) Resistance
1
(Internal trouble)
Between (A) (C) 79z
ness
PUMP (female) (A)
Possible causes PUMP (female) (C)
ness PUMP (female) (A) with wiring harness around Resistance Min. 1 Mz
3
PUMP (female) (C) with wiring harness around Resistance Min. 1 Mz
it
Between (11) (40) 79z
Between (11), (40) another wir-
Min. 1 Mz
ing harness
Circuit diagram related to fuel pump actuator
HD465-7, HD605-7 20-435

(10)
TROUBLESHOOTING [C318LK]
[C318LK] ABNORMALITY IN FUEL PUMP ACTUATOR
Action code Failure code Controller code Abnormality in fuel pump actuator
Trouble
Displayed pressure of fuel pump is excessively different from actual value.
Contents of trouble
Criteria for difference (for reference): 0.21 MPa {2.1 kg/cm2} (when coolant temperature is 38C)
Problem that
Engine speed is unstable.
appears on machine

Check fuel filter and piping directly for clogging, looseness, breakage,
and leakage.
piping
Suction of air caused by low Air may be sucked because of lowering of fuel level in tank. If fuel level
3
fuel level in tank gauge is in red range, supply fuel.
Possible causes Suction resistance of fuel filter may be large. Check fuel filter directly.
and standard value Large suction resistance of
4 Negative suction pressure
in normal state fuel filter 27 kPa {203 mmHg}
(Tank side)
Trouble in fuel pump actua-
5 Fuel pump actuator may malfunction. Check it directly.
tor
Defective electric system of
fuel pump pressure sensor
7 Trouble in injector Inside of injector may be defective. Check it directly.
Circuit diagram related to fuel pump actuator
20-436 HD465-7, HD605-7

(10)
TROUBLESHOOTING [C346KT]
[C346KT] ABNORMALITY IN POWER-DOWN UNIT OF ENGINE CONTROLLER
Action code Failure code Controller code Abnormality in power-down unit of engine controller
Trouble
E03 C346KT ENG (Engine controller system)
Contents of trouble Data recorded in power-down unit of engine controller has error.
Problem that Power-down data (maintenance information, current controller information, engine operating hours,
appears on machine etc.) are lost.
Charge level of battery can be checked in monitoring mode.
Related information (Code: 04301)

If fusible link is broken, circuit probably has short circuit with chassis
1 Defective fusible link (34 A)
ground.
Defective fuse
2 If fuse is broken, circuit probably has short circuit with chassis ground.
(FS1-1, FS1-4)
Disconnection in wiring har- Wiring harness between ECMB (female) (3)
BT2-(6) outlet
Wiring harness between ECMA (female) (4),
tor) (5) BT2-(30) outlet
Wiring harness between FS1 inlet fusible link
(FUA) battery relay terminal B
Possible causes
Short circuit in wiring har- BT2-(6) outlet with wiring harness around it
ness Wiring harness between ECMA (female) (4),
4
(with another wiring har- (5) BT2-(30) outlet with wiring harness Resistance Min. 1 Mz
ness) around it
Wiring harness between FS1 inlet fusible link
battery relay terminal B with wiring harness Resistance Min. 1 Mz
around it
5 Defective engine controller ECMA, ECMB Voltage
Between ECMB (3), (4), (5)
17.3 34.7 V
ECMA (7), (8)
HD465-7, HD605-7 20-437

(10)
TROUBLESHOOTING [C346KT]
Circuit diagram related to engine controller power supply
20-438 HD465-7, HD605-7

(1)
TROUBLESHOOTING [C423L6]
[C423L6] ABNORMALITY IN IN-RANGE OF TIMING RAIL PRESSURE SENSOR SYSTEM
Action code Failure code Controller code Abnormality in in-range of timing rail pressure sensor system
Trouble
E03 C423L6 ENG (Engine controller system)
Timing rail pressure sensor detected abnormal pressure.
Contents of trouble
Criterion (for reference): Min. 2.42 MPa {24.65 kg/cm2} when starting switch is turned on
Limits high idle speed to 1,500 rpm.
Problem that
appears on machine
Special cable (795-799-5480) is necessary for troubleshooting for timing rail pressure sensor.
Related information

Defective timing rail pres-
1 sure sensor TPR (male) Voltage
Between (C) (B) 0.42 0.58 V
Disconnection in wiring har- Wiring harness between ECMA (female) (5)
TPR (female) (A)
tor) TPR (female) (B)
TPR (female) (C)
Possible causes
and standard value
in normal state
ness TPR (female) (A) with wiring harness around it
3
TPR (female) (B) with wiring harness around it
TPR (female) (C) with wiring harness around it
Suction resistance of fuel filter may be large. Check fuel filter directly.
Large suction resistance of
fuel filter 27 kPa {203 mmHg}
(Tank side)
5 Defective engine controller ECMA (female) Resistance
Between (5) (18) 4.75 5.25 V
Between (33) (18) 0.42 0.58 V
HD465-7, HD605-7 20-439

(11)
Circuit diagram related to timing rail pressure sensor
20-440 HD465-7, HD605-7

(1)
[C431L4] ABNORMALITY IN IDLE VALIDATION SWITCH SYSTEM: *SEE SEPARATE

LIST (L4) (BOTH SIGNAL VOLTAGES OF 2 SYSTEMS ARE SENSED)
Action code Failure code Controller code Abnormality in idle validation switch system: *See separate list
Trouble
E01 C431L4 ENG (L4) (Both signal voltages of 2 systems are sensed)
Contents of trouble Both idle validation switch signals 2 and 3 are open (above 4.5 V).
Action of controller (The controller displays action code E01, CHECK/REPAIR.)
Problem that None in particular. (Since the controller controls according to the throttle sensor signal (potentiometer),
appears on machine no problems appear in the truck body.
Related information

2) Disconnect connector AS1.
3) Connect T-adapter.
Release the accelerator
Between AS1 pedal "Idle ON".
Idle validation switch defec-
1 (male) (4) (5) Press the accelerator pedal
tive Resistance Min. 1 Mz
"Idle OFF".
(male) (4) (6) Press the accelerator pedal
"Idle OFF".
2) Disconnect connectors ECMB and AS1.
2 AS1 (female) (6)
Possible causes contact) Resistance Max. 1 z
AS1 (female) (5)
and standard value
AS1 (female) (4)
Wiring harness between Resistance between ECMB
ECMB (female) (12) AS1 (female) (12), AS1 (female) Min. 1 M z
Ground fault in wiring har- (female) (6) (6) chassis ground
3
ECMB (female) (13) AS1 (female) (13), AS1 (female) Min. 1 Mz
(female) (5) (5) chassis ground
1) Connect the all connectors.
3) Press the accelerator pedal 3 times repeatedly.
4 Engine controller defective
Check that the failure code disappears.
a If the failure code does not disappear, replace the engine control-
ler.
HD465-7, HD605-7 20-441

(10)
Circuit diagram related to engine idle validation switch
20-442 HD465-7, HD605-7

(10)
[C432L5] ERROR IN IDLE VALIDATION PROCESS ( *SEE SEPARATE LIST (L5))
Action code Failure code Controller code Error in idle validation process: *See separate list (L5)
Trouble (Potentiometer signal and switch signal do not agree with each
E03 C432L5 ENG other)
The throttle potentiometer signal of the accelerator pedal is not conformed to idle validation switch sig-
Contents of trouble
nal 2 and signal 3.
The throttle is conformed to the idle validation switch (In idle: 0%, Off idle: 35%).
If this failure is detected when the throttle sensor signal is on the low speed side (idle side), the throttle
is conformed to the throttle sensor.
Problem that
The engine speed is kept at low idle or 1,500 rpm (Throttle: 35%).
appears on machine
Related information

"Idle OFF".
"Idle OFF".
2 AS1 (female) (6)
AS1 (female) (5)
Possible causes Wiring harness between ECMB (female) (21)
AS1 (female) (4)
in normal state
3
4) Connect connector.
4 Slottle sensor defective 5) Startin switch ON.
Between Release the accelerator
Voltage 0.35 0.55V
AS1 pedal "Idle ON".
(male) (1) Press the accelerator pedal
Voltage 3.55 3.75V
(2) "Idle OFF".
HD465-7, HD605-7 20-443

(10)

Possible causes 2) Turn the starting switch ON.
and standard value 3) Press the accelerator pedal 3 times repeatedly.
in normal state 5 Engine controller defective
ler.
Circuit diagram related to engine idle validation process
20-444 HD465-7, HD605-7

(10)
TROUBLESHOOTING [C441KX], [C442KG]
[C441KX] ABNORMALLY LOW LEVEL IN BATTERY VOLTAGE SYSTEM
Action code Failure code Controller code Abnormally low level in battery voltage system
Trouble
Contents of trouble Voltage of controller power supply circuit is below 12 V.
Problem that
appears on machine

and standard value
in normal state Carry out troubleshooting for failure code [C346KT].
[C442KG] ABNORMALLY HIGH LEVEL IN BATTERY VOLTAGE SYSTEM
Action code Failure code Controller code Abnormally low level in battery voltage system
Trouble
E01 C442KG ENG (Engine controller system)
Contents of trouble Voltage of controller power supply circuit is below 38 V.
Problem that
appears on machine

and standard value
in normal state Carry out troubleshooting for failure code [C346KT].
HD465-7, HD605-7 20-445

(10)
[C451KX] ABNORMALLY HIGH LEVEL IN FUEL RAIL PRESSURE SENSOR SYSTEM
Action code Failure code Controller code Abnormally high level in fuel rail pressure sensor system
Trouble
Contents of trouble Signal voltage of fuel rail pressure sensor circuit is above 4.78 V.
Opens and controls fuel rail.
Problem that
appears on machine
Special cable (795-799-5460) is necessary for troubleshooting for fuel rail pressure sensor.
Related information

Defective fuel rail pressure
1 sensor RPR Voltage
Between (C) (B) 0.42 0.58 V
RPR (female) (A)
RPR (female) (B)
tor)
Possible causes Wiring harness between ECMA (female) (31)
and standard value RPR (female) (C)
ness RPR (female) (A) with wiring harness around it
3
RPR (female) (B) with wiring harness around it
RPR (female) (C) with wiring harness around it
Between (5) (18) 4.75 5.25 V
Between (31) (18) 0.42 0.58 V
Circuit diagram related to fuel rail pressure sensor
20-446 HD465-7, HD605-7

(10)
[C452KX] ABNORMALLY LOW LEVEL IN FUEL RAIL PRESSURE SENSOR SYSTEM
Action code Failure code Controller code Abnormally low level in fuel rail pressure sensor system
Trouble
Contents of trouble Signal voltage of fuel rail pressure sensor circuit is below 0.15 V.
Reduces current for fuel rail actuator to 0 A.
Problem that
appears on machine

and standard value
HD465-7, HD605-7 20-447

(10)
[C455KZ] ABNORMAL CURRENT OF FUEL RAIL ACTUATOR
Action code Failure code Controller code Abnormal current of fuel rail actuator
Trouble
Current of fuel rail actuator circuit is out of normal range.
Contents of trouble
Problem that
appears on machine
Special cable (795-799-5470) is necessary for troubleshooting for fuel rail actuator.
Related information
Method of reproducing failure code: Turn starting switch ON or start engine.

Defective fuel rail actuator RAIL (male) Resistance
1
(Internal trouble)
Between (A) (C) 79z
ness
RAIL (female) (A)
RAIL (female) (C)
and standard value
Short circuit in wiring har- without turning starting switch ON.
ness Wiring harness between ECMA (female) (3)
3 Resistance Min. 1 Mz
(with another wiring har- RAIL (female) (A) with wiring harness around it
RAIL (female) (C) with wiring harness around it
Between (3) (10) 79z
Between (3), (10) another wiring
Min. 1 Mz
harness
Circuit diagram related to fuel rail actuator
20-448 HD465-7, HD605-7

(10)
TROUBLESHOOTING [C467LK], [C468LK]
[C467LK] ABNORMALITY IN TIMING RAIL ACTUATOR CONTROL
Action code Failure code Controller code Abnormality in timing rail actuator control
Trouble
Displayed timing rail fuel value is so different from quantity of actual timing fuel that target value cannot
Contents of trouble
be obtained.
Problem that
appears on machine

and standard value
in normal state Carry out troubleshooting for failure code [C112LK].
[C468LK] ABNORMALITY IN FUEL RAIL ACTUATOR CONTROL
Action code Failure code Controller code Abnormality in fuel rail actuator control
Trouble
Displayed injection rate of fuel rail is so different from actual injection rate that target value cannot be
Contents of trouble
obtained.
Limits maximum injection rate to 217 mm3/st.
Problem that
appears on machine

Possible causes leakage.
piping
and standard value
3 Trouble in fuel rail actuator Fuel pump actuator may have trouble in it. Check it directly.
in normal state
Clogging of fuel rail actuator
4 Fuel rail actuator screen may be clogged. Check it directly.
screen
5 Breakage of injector O-ring Injector O-ring may be broken. Check it directly.
HD465-7, HD605-7 20-449

(10)
TROUBLESHOOTING [C514LK]
[C514LK] ABNORMALITY IN FUEL RAIL ACTUATOR
Action code Failure code Controller code Abnormality in fuel rail actuator
Trouble
Displayed injection rate of fuel rail is excessively different from actual injection rate.
Contents of trouble
Criterion (for reference): Difference is 600 mm3/st for 50 msec or 250 mm3/st for 200 msec.
Limits maximum injection rate to 217 mm3/st.
Problem that
appears on machine

and standard value
in normal state Carry out troubleshooting for failure code [C468LK].
20-450 HD465-7, HD605-7

(10)
[C551L4] ABNORMALITY IN IDLE VALIDATION SWITCH SYSTEM: *SEE SEPARATE

LIST (L4) (EITHER SIGNAL VOLTAGE OF 2 SYSTEMS IS NOT SENSED)
Action code Failure code Controller code Abnormality in idle validation switch system: *See separate list
Trouble
E01 C551L4 ENG (L4) (Either signal voltage of 2 systems is not sensed)
Contents of trouble Both of idle validation switch signals 2 and 3 are closed (connected to GND).
Controller sets engine speed to low idle.
Problem that
Engine speed is kept at low idle.
appears on machine
Related information

"Idle OFF".
"Idle OFF".
2 AS1 (female) (6)
Possible causes contact) Resistance Max. 1 z
AS1 (female) (5)
and standard value
AS1 (female) (4)
3
3) Press the accelerator pedal 3 times repeatedly.
ler.
HD465-7, HD605-7 20-451

(10)
Circuit diagram related to idle validation switch
20-452 HD465-7, HD605-7

(10)
[C554L6] ABNORMALITY IN IN-RANGE OF FUEL RAIL PRESSURE SENSOR SYSTEM
Action code Failure code Controller code Abnormality in in-range of fuel rail pressure sensor system
Trouble
E03 C554L6 ENG (Engine controller system)
Fuel rail pressure sensor detected abnormal pressure.
Contents of trouble
Criterion (for reference): Min. 0.17 MPa {1.76 kg/cm2} when starting switch is turned on
Limits maximum injection rate to 270 mm3/st
Problem that
appears on machine
Special cable (795-799-5460) is necessary for troubleshooting for fuel rail pressure sensor.
Related information

Defective fuel rail pressure
1 sensor RPR Voltage
Between (C) (B) 0.42 0.58 V
Disconnection in wiring har- Wiring harness between ECMA (female) (5)
RPR (female) (A)
tor) RPR (female) (B)
RPR (female) (C)
Possible causes
and standard value
in normal state
ness RPR (female) (A) with wiring harness around it
3
RPR (female) (B) with wiring harness around it
RPR (female) (C) with wiring harness around it
Suction resistance of fuel filter may be large. Check fuel filter directly.
Large suction resistance of
fuel filter 27 kPa {203 mmHg}
(Tank side)
Between (5) (18) 4.75 5.25 V
Between (31) (18) 0.42 0.58 V
HD465-7, HD605-7 20-453

(11)
Circuit diagram related to fuel rail pressure sensor
20-454 HD465-7, HD605-7

(1)
TROUBLESHOOTING ENG-1
ENG-1 ENGINE DOES NOT START

Trouble Engine does not start
Not set Not set ENG
Contents of trouble Engine does not start.
Action of controller None in particular.
Problem that
Engine does not start.
appears on machine
If any failure code related to the engine controller or transmission controller is indicated, perform trou-
Related information
bleshooting for it first.

Specific gravity Min. 1.26
1 Battery defective
Voltage Min. 25 V
2) Replace R01 with normal one.
When engine starting relay (R01) No Relay (R01) normal
is replaced, is failure repaired? Yes Relay (R01) defective
2) Disconnect connector R01.
3) Check R01.
Engine starting relay (R01)
2
defective Between R01 (male) (1) (2) Resistance 200 400 z
3) Check R01.
4) Apply voltage between R01 (male) (1) (2).
Apply 24 V between
Between R01 (male) (1) (2).
(3) (6) Do not apply voltage
Resistance Max. 1 z
between (1) (2).
Possible causes
and standard value 1) Turn the starting switch OFF.
in normal state 2) Replace R02 with normal one.
When transmission neutral relay No Relay (R02) normal
(R02) is replaced, is failure repaired? Yes Relay (R02) defective
3) Check R02.
Transmission neutral relay
3
(R02) defective Between R02 (male) (1) (2) Resistance 200 400 z
3) Check R02.
Apply 24 V between
Resistance Max. 1 z
between (1) (2).
2) Replace diode (D01).
4 Diode (D01) defective 3) Turn the starting switch to the START position.
Failure is not repaired. Diode (D01) is normal.
Failure is repaired. Diode (D01) is defective.
HD465-7, HD605-7 20-455

(10)

Wiring harness between bat-
Voltage between battery ter-
tery battery terminal 01
minal 01 (B), 03 (B), 02 (M), 20 30 V
(B), 03 (B), 02 (M), and 04
and 04 (M) chassis ground
(M)
Disconnection of wiring har- 2) Disconnect fuse BT3 terminal (9) battery relay terminal 02 (M) and
5 ness between battery relay 04 (M).
and related wiring harness Wiring harness between bat- Resistance between battery
tery relay terminal 02 (M), 04 relay terminal 02 (M), 04 (M) Max. 1 z
(M) fuse BT3 (9) fuse BT3 (10)
2) Disconnect the negative (-) terminal of the battery relay.
Wiring harness between the negative (-) termi-
Resistance Max. 1 z
nal of the battery relay chassis ground
1) Turn the starting switch to the START position.
Disconnection in wiring har- Wiring harness between bat-
6 ness related to starting mo- tery relay terminal 02 (M), 04 Voltage between starting
tor terminal B motor terminal B chassis 20 30 V
(M) starting motor terminal
Possible causes ground
B
and standard value
in normal state
Failure is repaired. Diode (D01) is normal.
Failure is not repaired. Diode (D01) is defective.
2) Disconnect connector ATC3B, diode (D01), alternator terminal R,
and starting motor terminal R.
Hot short in wiring harness 3) Turn the starting switch ON.
8
of starting motor terminal R Wiring harness between di- Voltage between diode
ode (D01), starting motor (D01), starting motor termi-
Max. 12 V
terminal R, alternator ter- nal R (on the harness side),
minal R chassis ground
Alternator (Regulator) defec-
9 Voltage between starting motor terminal R chassis
tive Max. 12 V
ground
Failure is not repaired. Diode (D08) is normal.
20-456 HD465-7, HD605-7

(10)
Possible causes
and standard value Cause Standard value in normal state/Remarks on troubleshooting
in normal state
2) Disconnect connector R01, battery relay terminal 14 (BR), 12 (BR),
and starting switch terminals BR and C.
Wiring harness between Resistance between starting
starting switch terminal B switch terminal B battery
Max. 1 z
Disconnection in wiring har- battery relay terminals 01 (B) relay terminal 01 (B) and 03
ness and 03 (B). (B)
(Disconnection or defective Wiring harness between Resistance between starting
11
contact) starting switch terminal BR switch terminal BR battery
Max. 1 z
Wiring harness related to battery relay terminal 14 relay terminal 14 (BR), 12
starting switch (BR), 12 (BR) (BR)
aMeasure at starting switch terminal BR (+ side of tester) with a tester
in the diode range.
Wiring harness between Resistance between starting
starting switch terminal C switch terminal C R01 (fe- Max. 1 z
R01 (female) (3) male) (3)
2) Disconnect connectors R01 and R02, fuse BT3 terminal (10), and
starting motor terminal S.
Disconnection in wiring har- Wiring harness between Resistance between fuse
ness fuse BT3 terminal (10) R01 BT3 terminal (10) R01 (fe- Max. 1 z
Possible causes (Disconnection or defective (female) (1) male) (1)
and standard value 12 contact)
in normal state Wiring harness related to Wiring harness between Resistance between R01
engine starting relay (R01) R01 (female) (2) R02 (fe- (female) (2) R02 (female) Max. 1 z
male) (6) (6)
Wiring harness between Resistance between R01
R01 (female) (6) starting (female) (6) starting motor Max. 1 z
motor terminal S terminal S
Disconnection in wiring har- 2) Disconnect connector R02 and S2 (connector of shift lever side).
(Disconnection or defective Wiring harness between Resistance between R02
13 contact) R02 (female) (1) S2 (fe- (female) (1) S2 (female) Max. 1 z
Wiring harness related to male) (4) (4)
transmission neutral relay Wiring harness between Resistance between R02
(R02) R02 (female) (2), (3) chas- (female) (2), (3) chassis Max. 1 z
sis ground ground
1) Disconnect the starting switch terminals.
2) Check the starting switch.
14 Starting switch defective
Turn the starting switch to Resistance between termi-
Max. 1 z
the START position. nals B C
1) Check the starting motor.
15 Starting motor defective If the check result of the starting motor is normal, the starting motor
is normal.
HD465-7, HD605-7 20-457

(10)
Circuit diagram related to engine does not start
20-458 HD465-7, HD605-7

(1)
ENG-2 FAILURE IN PREHEATING

a) Engine is not preheated
Action code Failure code Controller code 1. Failure in preheating

Trouble
Not set Not set ENG a) Engine is not preheated
Contents of trouble Engine is not preheated. (Engine coolant temperature is below 0C.)
Problem that
Engine is not preheated.
appears on machine
Related information
bleshooting for it.

2) Disconnect connectors E11A, E12A, E11B, and E12B.
3) Check the disconnected connectors.
Between E11A chassis ground Resistance 19 25 z
When relay is
Resistance Max. 1 z
Between E12A opposite ON
Intake air heater relay defec- terminal of relay switch
1 When relay is
tive Resistance Min. 1M z
OFF
Between E11B chassis ground Resistance 19 25 z
When relay is
Resistance Max. 1 z
Between E12B opposite ON
terminal of relay switch When relay is
OFF
2) Disconnect the heater terminal.
Intake air heater (Ribbon 3) Check the heater.
2
heater) defective
Between heater terminal chassis
Resistance 0.17 0.27z
ground
Possible causes 1) Turn the starting switch OFF.
and standard value 2) Replace R37 with a normal relay.
in normal state 3) Turn the starting switch ON.
When the automatic preheater re- No Relay (R37) is normal.
lay (R37) is replaced, is failure re- Relay (R37) is defec-
paired? Yes
tive.
Automatic preheater relay 3) Check connector R37.
3
3) Check connector R37.
Apply 24 V between
Resistance Min. 1M z
Resistance Max. 1 z
between (1) (2).
Diode (E17A, E17B) defec- 2) Replace diode (E17A, E17B).
4
tive Failure is not repaired. Diode (D01) is normal.
HD465-7, HD605-7 20-459

(10)

2) Disconnect connectors ECMA, R37, E11A, E11B, E12A, E12B, and
fuse BT4 terminal (4).
Wiring harness between Resistance between ECMA
ECMA (female) (2) R37 (female) (2) R37 (female) Max. 1 z
(female) (1) (1)
Wiring harness between Resistance between R37
Disconnection in wiring har- R37 (female) (2) chassis (female) (2) chassis Max. 1 z
ness ground ground
5
contact) Wiring harness between
Resistance between R37
R37 (female) (5) E11A, Max. 1 z
(female) (5) E11A, E11B
Possible causes E11B
and standard value Wiring harness between Resistance between fuse
in normal state fuse BT4 terminal (4) R37 BT4 terminal (4) R37 (fe- Max. 1 z
(female) (3) male) (3)
Wiring harness between bat- Resistance between battery
tery relay terminal 02 (M), 04 relay terminal 02 (M), 04 (M) Max. 1 z
(M) E12A, E12B E12A, E12B
2) Disconnect connector ECMA.
4) Connect the connector.
6 Engine controller defective 5) Turn the starting switch ON.
6) Engine coolant temperature: Max. 0C
Between At the heater operation Voltage 20 30V
ECMA (2)
(7), (8) At the heater un operation Voltage Max. 1 V
20-460 HD465-7, HD605-7

(10)
Circuit diagram related to preheating
HD465-7, HD605-7 20-461

(1)
b) Preheating is actuated even under non-actuation conditions for preheating
Action code Failure code Controller code Failure in preheating

Trouble b) Preheating is actuated even under non-actuation conditions
Not set Not set ENG for preheating
Contents of trouble Preheating is actuated even under non-actuation conditions for preheating.
Problem that
Preheating is actuated even under non-actuation conditions for preheating.
appears on machine
Related information
bleshooting for it.

2) Disconnect connectors E11A, E12A, E11B, and E12B.
3) Check the disconnected connectors.
Between E11A chassis ground Resistance 19 25 z
When relay is
Resistance Max. 1 z
Between E12A opposite ON
Intake air heater relay defec- terminal of relay switch
1 When relay is
OFF
Between E11B chassis ground Resistance 19 25 z
When relay is
Resistance Max. 1 z
Between E12B opposite ON
terminal of relay switch When relay is
OFF
2) Disconnect the connector.
and standard value
in normal state Wiring harness between Voltage between ECMA (fe-
ECMA (female) (2) R37 male) (2), R37 (female) (1) Max. 1 V
(female) (1) chassis ground
2 Hot short in wiring harness
Wiring harness between Voltage between R37 (fe-
R37 (female) (5) E11A, male) (5), E11A, E11B Max. 1 V
E11B chassis ground
Wiring harness between Voltage between AC5A (fe-
AC5A (female) (20) HES male) (20), HES chassis Max. 1 V
(a) ground
Measure only on E12A side for wiring harness marked with (a).
2) Disconnect connector ECMA.
6) Engine coolant temperature: Max. 0 C
Between At the heater operation Voltage 20 30V
ECMA (2)
(7), (8) At the heater un operation Voltage Max. 1 V
20-462 HD465-7, HD605-7

(10)
Circuit diagram related to preheating time
HD465-7, HD605-7 20-463

(1)
ENG-3 AISS FUNCTION DOES NOT WORK NORMALLY

a) When AISS switch is set in AUTO, LOW SPEED control is selected
Action code Failure code Controller code When AISS switch is operated, AISS function does not work nor-
mally
Trouble
Not set Not set Not set a) When AISS switch is set in AUTO, LOW SPEED control is se-
lected
Contents of trouble When AISS switch is set in AUTO, LOW SPEED control is selected
Problem that
When AISS switch is set in AUTO, LOW SPEED control is selected
appears on machine
Related information Failure code is not indicated.

2) Disconnect connector AISS.
3) Check the connector.
1 AISS switch defective
Between AISS Set the AISS switch in AUTO Resistance Max. 1 z
(male) (1) (2) Set the AISS switch in LOW. Resistance Min. 1 Mz
Relay (R07) is
No
When AISS relay (R07) is replaced, is normal
failure corrected? Relay (R07) is
Yes
defective
2 AISS relay (R07) defective 3) Check the relay
Between R07 (male) (1) (2) Resistance 200 400 z
Possible causes 3) Check the relay.
and standard value 4) Apply voltage between R07 (male) (1) (2).
in normal state Apply 24 V between (1)
Between R07 (2).
(male) (3) (6) Do not apply 24 V between
Resistance Max. 1 z
(1) (2).
2) Disconnect connectors AISS, R07, fuse BT2 terminal (2).
Disconnection in wiring har- Wiring harness between fuse BT2 (2) AISS
3 (female) (1)
Wiring harness between AISS (female) (2)
R07 (female) (1)
Wiring harness between R07 (female) (2)
Resistance Max. 1 z
chassis ground
2) Disconnect connector ECMB.
Between ECMB Set the AISS switch in Voltage 20 30 V
(33) chassis AUTO.
ground Set the AISS switch in LOW. Voltage Max. 1 V
20-464 HD465-7, HD605-7

(10)
b) When AISS switch is set in LOW SPEED, AUTO control is selected
Action code Failure code Controller code When AISS switch is operated, AISS function does not work nor-
mally
Trouble
Not set Not set Not set b) When AISS switch is set in LOW SPEED, AUTO control is se-
lected
Contents of trouble When AISS switch is set in LOW SPEED, AUTO control is selected
Problem that
When AISS switch is set in LOW SPEED, AUTO control is selected
appears on machine
Related information Failure code is not indicated.

2) Disconnect connector AISS.
3) Check the connector.
1 AISS switch defective
Between AISS Set the AISS switch in AUTO Resistance Max. 1 z
(male) (1) (2) Set the AISS switch in LOW Resistance Min. 1 Mz
Relay (R07) is
No
When AISS relay (R07) is replaced, is normal
failure corrected? Relay (R07) is
Yes
defective
2 AISS relay (R07) defective 3) Check the relay
Possible causes 2) Disconnect connector R07.
and standard value 3) Check the relay.
in normal state 4) Apply voltage between R07 (male) (1) (2).
Apply 24 V between (1)
Between R07 (2).
(male) (3) (6) Do not apply 24 V between
Resistance Max. 1 z
(1) (2).
Disconnection in wiring har- 2) Disconnect connector R07.
3
chassis ground
2) Disconnect connectors AISS and R07.
Wiring harness be-
Wiring harness be-
tween AISS (female)
tween AISS (female) Voltage Max. 1 V
4 Hot short in wiring harness (2), R07 (female) (1)
(2) R07 (female) (1)
chassis ground
Wiring harness be-
Wiring harness be-
tween ECMB (female)
tween ECMB (female) Voltage Max. 1 V
(33), R07 (female) (6)
(33) R07 (female) (6)
chassis ground
HD465-7, HD605-7 20-465

(10)

Possible causes 3) Insert T-adapter.
and standard value 4) Connect the connector.
in normal state 5 Engine controller defective 5) Turn the starting switch ON.
Between ECMB Set the AISS switch in Voltage 20 30 V
(33) chassis AUTO.
ground Set the AISS switch in LOW. Voltage Max. 1 V
Circuit diagram related to low speed, auto control
20-466 HD465-7, HD605-7

(1)
TROUBLESHOOTING FOR TRANSMISSION
CONTROLLER SYSTEM
(TM MODE)
Electrical system diagram related to transmission control .......................................................................... 20-503

Information in troubleshooting table ....................................................................................................... 20-504
Phenomenon code table ........................................................................................................................ 20-505
[1380MW] Lockup clutch: Slip (MW)................................................................................................... 20-506
[1500L0] Detection of double engagement: *See separate list (L0) ................................................. 20-507
[15B0NX] Clogging of transmission oil filter: Clogging (NX) .............................................................. 20-508
[15E0KM] R to F gear shift abuse 1: Mistake in operation or setting (KM) ........................................ 20-509
[15E7KM] R to F gear shift abuse 2: Mistake in operation or setting (KM) ......................................... 20-509
[15G0MW] R clutch: Slip (MW)............................................................................................................ 20-510
[15H0MW] Hi clutch: Slip (MW) ........................................................................................................... 20-511
[15J0MW] Lo clutch: Slip (MW) ........................................................................................................... 20-513
[15K0MW] 1st clutch: Slip (MW).......................................................................................................... 20-515
[15L0MW] 2nd clutch: Slip (MW) ........................................................................................................ 20-516
[15M0MW] 3rd clutch: Slip (MW) ......................................................................................................... 20-517
[15N0MW] 4th clutch: Slip (MW) ......................................................................................................... 20-518
[15SBL1] R clutch solenoid: *See separate list (L1).......................................................................... 20-519
[15SBMA] R clutch solenoid: Malfunction (MA) .................................................................................. 20-520
[15SCL1] Hi clutch solenoid: *See separate list (L1)......................................................................... 20-521
[15SCMA] Hi clutch solenoid: Malfunction (MA) ................................................................................. 20-522
[15SDL1] Lo clutch solenoid: *Seee separate list (L1) ...................................................................... 20-523
[15SDMA] Lo clutch solenoid: Malfunction (MA)................................................................................. 20-524
[15SEL1] 1st clutch solenoid: *See separate list (L1) ....................................................................... 20-525
[15SEMA] 1st clutch solenoid: Malfunction (MA)................................................................................ 20-526
[15SFL1] 2nd clutch solenoid: *See separate list (L1) ...................................................................... 20-527
[15SFMA] 2nd clutch solenoid: Malfunction (MA)............................................................................... 20-528
[15SGL1] 3rd clutch solenoid: *See separate list (L1) ....................................................................... 20-529
[15SGMA] 3rd clutch solenoid: Malfunction (MA) ............................................................................... 20-530
[15SHL1] 4th clutch solenoid: *See separate list (L1) ....................................................................... 20-531
[15SHMA] 4th clutch solenoid: Malfunction (MA)................................................................................ 20-532
[15SJL1] Lockup clutch solenoid: 15SJ (L1)..................................................................................... 20-533
[15SJMA] Lockup clutch solenoid: 15SJ (MA) ................................................................................... 20-534
[2F00KM] Parking brake: Mistake in operation or setting (KM).......................................................... 20-535
[989A00] Engine overrun prevention command signal: Operation (00) ............................................ 20-537
[989AKZ] Engine overrun prevention command signal: Disconnection or short circuit (KZ) ............. 20-538
[AA10NX] Air cleaner element: Clogging (NX) ................................................................................... 20-539
[AB00MA] Alternator: Malfunction (MA).............................................................................................. 20-541
[B@BCZK] Lowering of radiator water: Lowering of level (ZK) ............................................................ 20-543
[D1BOKZ] Transmission controller cutout: Disconnection or short circuit (KZ) .................................. 20-544
[D5ZMKZ] Disconnection, grounding fault, or short circuit in engine output mode command line:
Disconnection or short circuit (KZ) .................................................................................... 20-546
[DAQ0KK] Transmission controller: Lowering of source/input voltage (KK) ....................................... 20-547
[DAQ1KK] Main power line of transmission controller: Lowering of source/input voltage (KK) .......... 20-549
[DAQ2KK] Transmission controller load power line: Lowering of source/input voltage (KK) ............. 20-551
[DAQ3KK] Direct line of transmission controller battery: Lowering of source/input voltage (KK) ........ 20-553
[DAQ9KM] Transmission controller wiring harness: Mistake in operation or setting (KM) .................. 20-554
[DAQ9KQ] Transmission controller wiring harness: Disagreement of model selection signals (KQ) .. 20-555
[DAQAKQ] Transmission controller rotary switch: Disagreement of model selection signals (KQ) ..... 20-556
[DAQSMA] Transmission controller: Malfunction (MA) ........................................................................ 20-556
HD465-7, HD605-7 20-501

(10)
TESTING AND ADJUSTING INVERTED TYPE
TROUBLESHOOTING REAR SUSPENSION CYLINDER
[DDTGKA] Lockup clutch fill switch: Disconnection (KA) .................................................................... 20-557

[DDTHKA] Hi clutch fill switch: Disconnection (KA)............................................................................. 20-558
[DDTJKA] Lo clutch fill switch: Disconnection (KA) ............................................................................ 20-559
[DDTKKA] 1st clutch fill switch: Disconnection (KA) ........................................................................... 20-560
[DDTLKA] 2nd clutch fill switch: Disconnection (KA) .......................................................................... 20-561
[DDTMKA] 3rd clutch fill switch: Disconnection (KA)........................................................................... 20-562
[DDTNKA] R clutch fill switch: Disconnection (KA) ............................................................................. 20-563
[DDTPKA] 4th clutch fill switch: Disconnection (KA) ........................................................................... 20-564
[DF10KA] Shift lever: Disconnection (KA) .......................................................................................... 20-565
[DF10KB] Shift lever: Short circuit (KB) ............................................................................................. 20-569
[DGF1KX] Transmission valve oil temperature sensor: Out of input signal range (KX) ...................... 20-572
[DGT1KX] Torque converter oil temperature sensor: Out of inputsignal range (KX) .......................... 20-574
[DHT5KX] Torque converter oil pressure sensor: Out of input signal range (KX) .............................. 20-575
[DHT5L6] Torque converter oil pressure sensor: See separate list (L6) ........................................... 20-577
[DJF1KA] Fuel level sensor: Disconnection (KA) ............................................................................... 20-578
[DK11KX] Throttle angle sensor: Out of input signal range (KX) ....................................................... 20-579
[DLE2KA] Engine speed sensor: Disconnection (KA) ........................................................................ 20-581
[DLE2LC] Engine speed sensor: *See separate list (LC) ................................................................... 20-582
[DLF1KA] Transmission input shaft speed sensor: Disconnection (KA) ............................................ 20-583
[DLF1LC] Transmission input shaft speed sensor: *See separate list (LC) ....................................... 20-584
[DLF2KA] Transmission intermediate shaft speed sensor: Disconnection (KA) ................................ 20-585
[DLF2LC] Transmission intermediate shaft speed sensor: *See separate list (LC) .......................... 20-586
[DLT3KA] Transmission output shaft speed sensor: Disconnection (KA) .......................................... 20-587
[DLT3LC] Transmission output shaft speed sensor: *See separate list (LC) ..................................... 20-588
[DXH1KA] Disconnection in output circuit of lockup clutch solenoid: Disconnection (KA) .................. 20-590
[DXH1KB] Short circuit in output circuit of lockup clutch solenoid: Short circuit (KB) ......................... 20-591
[DXH2KA] Disconnection in output circuit of Hi clutch solenoid: Disconnection (KA) ......................... 20-592
[DXH2KB] Short circuit in output circuit of Hi clutch solenoid: Short circuit (KB) ............................... 20-593
[DXH3KA] Disconnection in output circuit of Lo clutch solenoid: Disconnection (KA) ........................ 20-595
[DXH3KB] Short circuit in output circuit of Lo clutch solenoid: Short circuit (KB) ............................... 20-596
[DXH4KA] Disconnection in output circuit of 1st clutch solenoid: Disconnection (KA) ....................... 20-598
[DXH4KB] Short circuit in output circuit of 1st clutch solenoid: Short circuit (KB) ............................... 20-599
[DXH5KA] Disconnection in output circuit of 2nd clutch solenoid: Disconnection (KA) ...................... 20-600
[DXH5KB] Short circuit in output circuit of 2nd clutch solenoid: Short circuit (KB) ............................. 20-601
[DXH6KA] Disconnection in output circuit of 3rd clutch solenoid: Disconnection (KA) ....................... 20-602
[DXH6KB] Short circuit in output circuit of 3rd clutch solenoid: Short circuit (KB) .............................. 20-603
[DXH7KA] Disconnection in output circuit of R clutch solenoid: Disconnection (KA) .......................... 20-604
[DXH7KB] Short circuit in output circuit of R clutch solenoid: Short circuit (KB) ................................. 20-605
[DXHHKA] Disconnection in output circuit of 4th clutch solenoid: Disconnection (KA) ....................... 20-606
[DXHHKB] Short circuit in output circuit of 4th clutch solenoid: Short circuit (KB) .............................. 20-607
TM-1 Fuel level gauge does not operate normally (It always indicates "FULL") ........................ 20-608
TM-2 Abnormality in backup lamp and backup buzzer ............................................................... 20-609
a) When the shift lever is set in the "R" position, the backup lamp and backup buzzer
are not turned ON.......................................................................................................... 20-609
b) Backup lamp is not turned ON (Backup buzzer is normal)............................................ 20-610
c) Backup buzzer is not turned ON (Backup lamp is normal) ........................................... 20-610
d) While shift lever is not operated, backup lamp and backup buzzer are turned ON ...... 20-611
20-502 HD465-7, HD605-7

(2)
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED TO TRANSMISSION CONTROL
ELECTRICAL SYSTEM DIAGRAM RELATED TO TRANSMISSION CONTROL

a For details of this page, see page 90-19.
HD465-7, HD605-7 20-503

(2)

The following information is summarized in the troubleshooting table and the related electrical circuit dia-
panel panel panel
Action of controller Action taken by controller to protect system or devices when monitor panel or controller detects trouble
Problem that
appears on machine

Remarks on judgment
1
Disconnection
Ground fault
Short circuit
indicate priority)
Insert or connect T-adapter as explained below for troubleshooting,
side.
side.
5
side.
20-504 HD465-7, HD605-7

(10)
TROUBLESHOOTING PHENOMENON CODE TABLE






MW Sliding
NS Overheat
HD465-7, HD605-7 20-505

(10)
TROUBLESHOOTING [1380MW]
[1380MW] LOCKUP CLUTCH: SLIP (MW)
Action code Failure code Controller code Lockup clutch: Slip (MW)
Trouble (Command is Holding pressure, fill switch is ON, and slip is
E03 1380MW TM sensed)
When a signal is output to the lockup clutch ECMV, the value calculated from the signals of the engine
Contents of trouble speed sensor, transmission input shaft speed sensor, transmission intermediate shaft speed sensor,
and transmission output shaft speed sensor is abnormal.
The controller keeps the current gear speed and turns the lockup operation OFF.
If the shift lever is set in the "N" position, the controller keeps the gear in Neutral.
Problem that The lockup operation is reset and the gear cannot be shifted.
appears on machine If the shift lever is set in the "N" position, the machine cannot start until it is stopped.
This failure can be checked in the monitoring function (Code: 31519, 31609, 31619).
Related information If the electric system is normal, check the hydraulic/mechanical system of the lockup clutch and pres-
sure control valve for a defect.

2) Disconnect connector CN20.
Lockup clutch ECMV defec- 3) Connect T-adapter.
1
tive
Between CN20 (male) (1) (2) Resistance 5 15 z
Between CN20 (male) (1), (2) chassis ground Resistance Min. 1 Mz
2) Disconnect connector ATC2 and CN10.
Disconnection in wiring har- 3) Connect T-adapter.
Possible causes ness
and standard value 2 (Disconnection or defective Wiring harness between ATC2 (female) (10) Resistance Max. 1 z
in normal state CN20 (female) (1)
contact)
Wiring harness between ATC2 (female) (20)
Resistance Max. 1 z
CN20 (female) (2)
Defective sensing by speed
3 Troubleshooting by the failure codes of DL**KA, and DL**LC.
sensor
2) Disconnect connector ATC2.
Transmission controller de- 3) Connect T-adapter.
4
fective
Resistance 5 15 z
ATC2 (female) (20)
20-506 HD465-7, HD605-7

(10)
TROUBLESHOOTING [1500L0]
[1500L0] DETECTION OF DOUBLE ENGAGEMENT: *SEE SEPARATE LIST (L0)

Trouble Detection of double engagement: *See separate list (L0)
E03 1500L0 TM
Contents of trouble The fill switch signals of abnormally combined 2 clutches are input.
Action of controller The gear is set in Neutral during travel and the machine cannot start again.
Problem that The transmission cutout relay is turned OFF.
appears on machine The gear is set in Neutral.
Another failure (Clutch pressure control valve system failure code: 15S*L1) occurs simultaneously with
Related information
this failure.

Clutch pressure control
Possible causes
1 valve system failure code Perform troubleshooting by the indicated failure code.
and standard value
(15S*L1) is indicated.
in normal state
Transmission controller de-
2 Perform troubleshooting by the indicated failure code.
fective
HD465-7, HD605-7 20-507

(10)
TROUBLESHOOTING [15B0NX]
[15B0NX] CLOGGING OF TRANSMISSION OIL FILTER: CLOGGING (NX)

Trouble Clogging of transmission oil filter: Clogging (NX)
E01 15B0NX TM
When the torque converter oil temperature is above 50C, the signal circuit of the transmission clogging
Contents of trouble
sensor is opened (disconnected from GND).
Problem that
If the machine is used without repairing, dust may enter the transmission circuit.
appears on machine
This failure can be checked in the monitoring function (Code: 33300).
Related information After repairing the failure and confirming resetting of the machine, perform the initial learning of the
transmission controller, referring to TESTING AND ADJUSTING, "Inspection of machine monitor".

Clogging of transmission fil-
1 Clean or replace.
ter
2) Disconnect connectors ATC5A, TMF and CN10.
Transmission filter clogging 3) Connect T-adapter.
2
sensor defective
Between TMF (male) Filter is normal. Resistance Max. 1 z
(1) (2) Filter is clogged. Resistance Min. 1 Mz
2) Disconnect connectors ATC5A, TNF, and CN10.
Possible causes Disconnection in wiring har- 3) Connect T-adapter.
and standard value ness
in normal state 3 Wiring harness between ATC5A (female) (6)
(Disconnection or defective Resistance Max. 1 z
TMF (female) (1)
contact)
Wiring harness between CJH1 (female) (5)
Resistance Max. 1 z
TMF (female) (2)
2) Disconnect connectors ATC5A and ATC3A.
Transmission controller de- 4) Connect conector.
4
Between ATC5A (6) Filter is normal. Voltage Max. 1 V
chassis ground Filter is clogged. Voltage 20 30 V
20-508 HD465-7, HD605-7

(10)
TROUBLESHOOTING [15E0KM], [15E7KM]
[15E0KM] R TO F GEAR SHIFT ABUSE 1: MISTAKE IN OPERATION OR SETTING (KM)

Trouble R to F gear shift abuse 1: Mistake in operation or setting (KM)
Not set 15E0KM TM
When the output shaft speed is 200 rpm 300 rpm (approx. 5 7 km/h), the gear is shifted from reverse
Contents of trouble
to forward.
Problem that If the machine is used without repairing, it may be broken.
appears on machine The failure is only recorded in the failure history.
Related information This failure can be checked in the monitoring function (Code: 31400).

and standard value
in normal state 1 Abuse Change the travel direction after the machine is stopped perfectly.
[15E7KM] R TO F GEAR SHIFT ABUSE 2: MISTAKE IN OPERATION OR SETTING (KM)

Trouble R to F gear shift abuse 2: Mistake in operation or setting (KM)
Not set 15E7KM TM
When the output shaft speed is above 300 rpm (approx. 7 km/h), the gear is shifted from reverse to
Contents of trouble
forward.
Problem that If the machine is used without repairing, it may be broken.
appears on machine The failure is only recorded in the failure history.

and standard value
in normal state 1 Abuse Change the travel direction after the machine is stopped perfectly.
HD465-7, HD605-7 20-509

(10)
TROUBLESHOOTING [15G0MW]
[15G0MW] R CLUTCH: SLIP (MW)
Action code Failure code Controller code R clutch: Slip (MW)

E03 15G0MW TM sensed)
When a signal is output to the R clutch ECMV, the value calculated from the signals of the transmission
Contents of trouble input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission output shaft
speed sensor is abnormal.
Action of controller The controller sets the gear in Neutral.
Problem that
The gear is set in Neutral suddenly during travel and the machine cannot start again.
appears on machine
Related information If the electric system is normal, check the hydraulic/mechanical system of the R clutch and pressure
control valve for a defect.

1 R clutch ECMV defective 3) Connect T-adapter.
contact)
Resistance Max. 1 z
CN10 (female) (2)
sensor
4
fective
Resistance 5 15 z
ATC2 (female) (15)
20-510 HD465-7, HD605-7

(10)
TROUBLESHOOTING [15H0MW]
[15H0MW] HI CLUTCH: SLIP (MW)
Action code Failure code Controller code Hi clutch: Slip (MW)

E03 15H0MW TM sensed)
When a signal is output to the Hi clutch ECMV, the value calculated from the signals of the transmission
Problem that
The gear is set in Neutral suddenly during travel.
appears on machine
Related information If the electric system is normal, check the hydraulic/mechanical system of the Hi clutch and pressure

1 Hi clutch ECMV defective 3) Connect T-adapter.
contact)
Resistance Max. 1 z
CN18 (female) (2)
sensor
4
fective
Resistance 5 15 z
ATC2 (female) (19)
HD465-7, HD605-7 20-511

(10)
TROUBLESHOOTING [15H0MW]
20-512 HD465-7, HD605-7

(7)
TROUBLESHOOTING [15J0MW]
[15J0MW] LO CLUTCH: SLIP (MW)
Action code Failure code Controller code Lo clutch: Slip (MW)

E03 15J0MW TM sensed)
When a signal is output to the Lo clutch ECMV, the value calculated from the signals of the transmission
Problem that
appears on machine
Related information If the electric system is normal, check the hydraulic/mechanical system of the Lo clutch and pressure

1 Lo clutch ECMV defective 3) Connect T-adapter.
contact)
Resistance Max. 1 z
CN16 (female) (2)
sensor
4
fective
Resistance 5 15 z
ATC2 (female) (17)
HD465-7, HD605-7 20-513

(10)
TROUBLESHOOTING [15J0MW]
20-514 HD465-7, HD605-7

(7)
TROUBLESHOOTING [15K0MW]
[15K0MW] 1ST CLUTCH: SLIP (MW)
Action code Failure code Controller code 1st clutch: Slip (MW)
E03 15K0MW TM sensed)
When a signal is output to the 1st clutch ECMV, the value calculated from the signals of the transmis-
Contents of trouble sion input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission output
shaft speed sensor is abnormal.
Problem that
appears on machine
Related information If the electric system is normal, check the hydraulic/mechanical system of the 1st clutch and pressure

1 1st clutch ECMV defective 3) Connect T-adapter.
contact)
Resistance Max. 1 z
CN6 (female) (2)
sensor
4
fective
Resistance 5 15 z
ATC2 (female) (13)
HD465-7, HD605-7 20-515

(10)
TROUBLESHOOTING [15L0MW]
[15L0MW] 2ND CLUTCH: SLIP (MW)
Action code Failure code Controller code 2nd clutch: Slip (MW)
E03 15L0MW TM sensed)
When a signal is output to the 2nd clutch ECMV, the value calculated from the signals of the transmis-
Problem that
appears on machine
Related information If the electric system is normal, check the hydraulic/mechanical system of the 2nd clutch and pressure

1 2nd clutch ECMV defective 3) Connect T-adapter.
contact)
Resistance Max. 1 z
CN8 (female) (2)
sensor
4
fective
Resistance 5 15 z
ATC2 (female) (15)
20-516 HD465-7, HD605-7

(10)
TROUBLESHOOTING [15M0MW]
[15M0MW] 3RD CLUTCH: SLIP (MW)
Action code Failure code Controller code 3rd clutch: Slip (MW)
E03 15M0MW TM sensed)
When a signal is output to the 3rd clutch ECMV, the value calculated from the signals of the transmis-
Problem that
appears on machine
Related information If the electric system is normal, check the hydraulic/mechanical system of the 3rd clutch and pressure

1 3rd clutch ECMV defective 3) Connect T-adapter.
contact)
Resistance Max. 1 z
CN12 (female) (2)
sensor
4
fective
Resistance 5 15 z
ATC2 (female) (18)
HD465-7, HD605-7 20-517

(10)
TROUBLESHOOTING [15N0MW]
[15N0MW] 4TH CLUTCH: SLIP (MW)
Action code Failure code Controller code 4th clutch: Slip (MW)
E03 15N0MW TM sensed)
When a signal is output to the 4th clutch ECMV, the value calculated from the signals of the transmis-
Problem that
appears on machine
Related information If the electric system is normal, check the hydraulic/mechanical system of the 4th clutch and pressure

1 4th clutch ECMV defective 3) Connect T-adapter.
contact)
Resistance Max. 1 z
CN14 (female) (2)
sensor
4
fective
Resistance 5 15 z
ATC2 (female) (13)
20-518 HD465-7, HD605-7

(10)
TROUBLESHOOTING [15SBL1]
[15SBL1] R CLUTCH SOLENOID: *SEE SEPARATE LIST (L1)
Action code Failure code Controller code R clutch solenoid: *See separate list (L1)
Trouble
E03 15SBL1 TM (Command is OFF and fill switch is ON)
When the output to the R clutch ECMV is turned OFF, the signal from the fill switch is kept ON and the
Contents of trouble
clutch is not disengaged.
Problem that
appears on machine
Related information This failure can be checked in the monitoring function (Code: 31516, 31606, 31616).

1 R clutch fill switch defective When dis-
Between CN11 (male) (1) chas- engaged
sis ground When en-
Resistance Max. 1 z
gaged
2) Disconnect connectors ATC5A and CN11.
Possible causes
and standard value Ground fault in wiring har-
in normal state 2 Resistance between
ness
Wiring harness between ATC5A ATC5A (female) (16),
Min. 1 Mz
(female) (16) CN11 (female) (1) CN11 (female) (1)
chassis ground
3 When dis-
fective Resistance Min. 1 Mz
Between ATC5A (female) (16) engaged
chassis ground When en-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-519

(10)
TROUBLESHOOTING [15SBMA]
[15SBMA] R CLUTCH SOLENOID: MALFUNCTION (MA)
Action code Failure code Controller code R clutch solenoid: Malfunction (MA)
E03 15SBMA TM sensed)
When a signal is output to the R clutch ECMV, the signal from the fill switch is kept OFF and the value
Contents of trouble calculated from the signals of the transmission input shaft speed sensor, transmission intermediate
shaft speed sensor, and transmission output shaft speed sensor is abnormal.
Problem that
appears on machine
Related information If the electric system is normal, check the hydraulic/mechanical system of the R clutch and pressure

contact)
Resistance Max. 1 z
CN10 (female) (2)
sensor
4
fective
Resistance 5 15 z
ATC2 (female) (15)
20-520 HD465-7, HD605-7

(10)
TROUBLESHOOTING [15SCL1]
[15SCL1] HI CLUTCH SOLENOID: *SEE SEPARATE LIST (L1)

Action code Failure code Controller code Hi clutch solenoid: *See separate list (L1)
Trouble
E03 15SCL1 TM (Command is OFF and fill switch is ON)
When the output to the Hi clutch ECMV is turned OFF, the signal from the fill switch is kept ON and the
Contents of trouble
Problem that
appears on machine

1 Hi clutch fill switch defective When dis-
sis ground When en-
Resistance Max. 1 z
gaged
Possible causes
ness
Min. 1 Mz
chassis ground
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-521

(10)
TROUBLESHOOTING [15SCMA]
[15SCMA] HI CLUTCH SOLENOID: MALFUNCTION (MA)

Action code Failure code Controller code Hi clutch solenoid: Malfunction (MA)
E03 15SCMA TM sensed)
When a signal is output to the Hi clutch ECMV, the signal from the fill switch is kept OFF and the value
Problem that
appears on machine
Related information If the electric system is normal, check the hydraulic/mechanical system of the Hi clutch and pressure

and standard value 2 (Disconnection or defective
Resistance Max. 1 z
contact)
Resistance Max. 1 z
CN18 (female) (2)
sensor
4
fective
Resistance 5 15 z
ATC2 (female) (19)
20-522 HD465-7, HD605-7

(10)
TROUBLESHOOTING [15SDL1]
[15SDL1] LO CLUTCH SOLENOID: *SEE SEPARATE LIST (L1)

Action code Failure code Controller code Lo clutch solenoid: *See separate list (L1)
Trouble
E03 15SDL1 TM (Command is OFF and fill switch is ON)
When the output to the Lo clutch ECMV is turned OFF, the signal from the fill switch is kept ON and the
Contents of trouble
Problem that
appears on machine

1 Lo clutch fill switch defective When dis-
sis ground When en-
Resistance Max. 1 z
gaged
Possible causes
ness
Min. 1 Mz
chassis ground
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-523

(10)
TROUBLESHOOTING [15SDMA]
[15SDMA] LO CLUTCH SOLENOID: MALFUNCTION (MA)

Action code Failure code Controller code Lo clutch solenoid: Malfunction (MA)
E03 15SDMA TM sensed)
When a signal is output to the Lo clutch ECMV, the signal from the fill switch is kept OFF and the value
Problem that
appears on machine
Related information If the electric system is normal, check the hydraulic/mechanical system of the Lo clutch and pressure

Resistance Max. 1 z
contact)
Resistance Max. 1 z
CN16 (female) (2)
sensor
4
fective
Resistance 5 15 z
ATC2 (female) (17)
20-524 HD465-7, HD605-7

(10)
TROUBLESHOOTING [15SEL1]
[15SEL1] 1ST CLUTCH SOLENOID: *SEE SEPARATE LIST (L1)
Action code Failure code Controller code 1st clutch solenoid: *See separate list (L1)
Trouble
E03 15SEL1 TM (Command is OFF and fill switch is ON)
When the output to the 1st clutch ECMV is turned OFF, the signal from the fill switch is kept ON and
Contents of trouble
the clutch is not disengaged.
Problem that
appears on machine

1 1st clutch fill switch defective When dis-
Between CN7 (male) (1) chassis engaged
ground When en-
Resistance Max. 1 z
gaged
Possible causes
ness
Min. 1 Mz
chassis ground
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-525

(10)
TROUBLESHOOTING [15SEMA]
[15SEMA] 1ST CLUTCH SOLENOID: MALFUNCTION (MA)
Action code Failure code Controller code 1st clutch solenoid: Malfunction (MA)
E03 15SEMA TM sensed)
When a signal is output to the 1st clutch ECMV, the signal from the fill switch is kept OFF and the value
Problem that
appears on machine
Related information If the electric system is normal, check the hydraulic/mechanical system of the 1st clutch and pressure

2) Disconnect connector ATC2 CN6.
contact)
Resistance Max. 1 z
CN6 (female) (2)
sensor
4
fective
Resistance 5 15 z
ATC2 (female) (13)
20-526 HD465-7, HD605-7

(10)
TROUBLESHOOTING [15SFL1]
[15SFL1] 2ND CLUTCH SOLENOID: *SEE SEPARATE LIST (L1)
Action code Failure code Controller code 2nd clutch solenoid: *See separate list (L1)
Trouble
E03 15SFL1 TM (Command is OFF and fill switch is ON)
When the output to the 2nd clutch ECMV is turned OFF, the signal from the fill switch is kept ON and
Contents of trouble
Problem that
appears on machine

2nd clutch fill switch defec-
1 When dis-
ground When en-
Resistance Max. 1 z
gaged
Possible causes
ness
Min. 1 Mz
chassis ground
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-527

(10)
TROUBLESHOOTING [15SFMA]
[15SFMA] 2ND CLUTCH SOLENOID: MALFUNCTION (MA)
Action code Failure code Controller code 2nd clutch solenoid: Malfunction (MA)
E03 15SFMA TM sensed)
When a signal is output to the 2nd clutch ECMV, the signal from the fill switch is kept OFF and the value
Problem that
appears on machine
Related information If the electric system is normal, check the hydraulic/mechanical system of the 2nd clutch and pressure

Between CN8 (male)(1) , (2) chassis ground Resistance Min. 1 Mz
contact)
Resistance Max. 1 z
CN8 (female) (2)
sensor
4
fective
Resistance 5 15 z
ATC2 (female) (15)
20-528 HD465-7, HD605-7

(10)
TROUBLESHOOTING [15SGL1]
[15SGL1] 3RD CLUTCH SOLENOID: *SEE SEPARATE LIST (L1)
Action code Failure code Controller code 3rd clutch solenoid: *See separate list (L1)
Trouble
E03 15SGL1 TM (Command is OFF and fill switch is ON)
When the output to the 3rd clutch ECMV is turned OFF, the signal from the fill switch is kept ON and
Contents of trouble
Problem that
appears on machine

3rd clutch fill switch defec-
1 When dis-
sis ground When en-
Resistance Max. 1 z
gaged
Possible causes
ness
Min. 1 Mz
chassis ground
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-529

(10)
TROUBLESHOOTING [15SGMA]
[15SGMA] 3RD CLUTCH SOLENOID: MALFUNCTION (MA)
Action code Failure code Controller code 3rd clutch solenoid: Malfunction (MA)
E03 15SGMA TM sensed)
When a signal is output to the 3rd clutch ECMV, the signal from the fill switch is kept OFF and the value
Problem that
appears on machine
Related information If the electric system is normal, check the hydraulic/mechanical system of the 3rd clutch and pressure

contact)
Resistance Max. 1 z
CN12 (female) (2)
sensor
4
fective
Resistance 5 15 z
ATC2 (female) (18)
20-530 HD465-7, HD605-7

(10)
TROUBLESHOOTING [15SHL1]
[15SHL1] 4TH CLUTCH SOLENOID: *SEE SEPARATE LIST (L1)
Action code Failure code Controller code 4th clutch solenoid: *See separate list (L1)
Trouble
E03 15SHL1 TM (Command is OFF and fill switch is ON)
When the output to the 4th clutch ECMV is turned OFF, the signal from the fill switch is kept ON and
Contents of trouble
Problem that
appears on machine

4th clutch fill switch defec-
1 When dis-
sis ground When en-
Resistance Max. 1 z
gaged
Possible causes
ness
Min. 1 Mz
chassis ground
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-531

(10)
TROUBLESHOOTING [15SHMA]
[15SHMA] 4TH CLUTCH SOLENOID: MALFUNCTION (MA)
Action code Failure code Controller code 4th clutch solenoid: Malfunction (MA)
E03 15SHMA TM sensed)
When a signal is output to the 4th clutch ECMV, the signal from the fill switch is kept OFF and the value
Problem that
appears on machine
Related information If the electric system is normal, check the hydraulic/mechanical system of the 4th clutch and pressure

contact)
Resistance Max. 1 z
CN14 (female) (2)
sensor
4
fective
Resistance 5 15 z
ATC2 (female) (13)
20-532 HD465-7, HD605-7

(10)
TROUBLESHOOTING [15SJL1]
[15SJL1] LOCKUP CLUTCH SOLENOID: 15SJ (L1)
Action code Failure code Controller code Lockup clutch solenoid: 15SJ (L1)
Trouble
E03 15SJL1 TM (Command is OFF and fill switch is ON)
When the output to the lockup clutch ECMV is turned OFF, the signal from the fill switch is kept ON and
Contents of trouble
If the shift lever is set in the "N" position, the controller keeps the gear in neutral.

Lockup clutch fill switch de-
1 When dis-
sis ground When en-
Resistance Max. 1 z
gaged
Possible causes
ness
Min. 1 Mz
chassis ground
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-533

(10)
TROUBLESHOOTING [15SJMA]
[15SJMA] LOCKUP CLUTCH SOLENOID: 15SJ (MA)
Action code Failure code Controller code Lockup clutch solenoid: 15SJ (MA)
Trouble
E03 15SJMA TM (Command is OFF, fill switch is ON, and slip is sensed)
When a signal is output to the lockup clutch ECMV, the signal from the fill switch is kept OFF and the
Contents of trouble value calculated from the signals of the engine speed sensor, transmission intermediate shaft speed
sensor, and transmission output shaft speed sensor is abnormal.
Related information If the electric system is normal, check the hydraulic/mechanical system of the lockup clutch and pres-
sure control valve for a defect.

Lockup clutch ECMV 3) Connect T-adapter.
1
defective
2) Disconnect connector ATC5A and CN20.
contact)
Resistance Max. 1 z
CN20 (female) (2)
sensor
4
fective
Resistance 5 15 z
ATC2 (female) (20)
20-534 HD465-7, HD605-7

(10)
TROUBLESHOOTING [2F00KM]
[2F00KM] PARKING BRAKE: MISTAKE IN OPERATION OR SETTING (KM)
Action code Failure code Controller code Parking brake: Mistake in operation or setting (KM)
Trouble
Not set 2F00KM TM (Parking brake drags)
When the output shaft speed is above 200 rpm (approx. 5 km/h), the parking brake or emergency brake
Contents of trouble
is operated.
Problem that
If the machine is used without repairing, it may be broken.
appears on machine

Set the parking brake switch in the FREE position and then start the
Mistake in operation of park- machine.
1
ing brake switch Stop the machine perfectly, and then set the emergency brake switch
in the FREE position and start the machine.
Relay
Yes
When the parking brake relay (R03) is re- (R03)
placed, is failure repaired? Relay
No
(R03)
Parking brake relay (R03) 3) Check the relay.
2
defective Between R03 (male) (1) (2) Resistance 200 400 z
in normal state
Apply 24 V between
(3) (6) Do not apply 24 V be-
Resistance Max. 1 z
tween (1) (2).
2) Disconnect connector PSW.
4) Start the engine.
Parking brake oil pressure Set parking brake
3
switch defective switch in FREE posi- Resistance Min. 1 Mz
Between PSW (male) position.
(1) (2) Set parking brake
switch in PARK posi- Resistance Max. 1 z
tion.
Mistake in operation of
emergency brake
4 Operate the emergency brake only when necessary.
(Operation of emergency
brake during travel)
HD465-7, HD605-7 20-535

(10)
TROUBLESHOOTING [2F00KM]

Wiring harness between R03 (female) (2), (6)
Resistance Max. 1 z
Disconnection in wiring har- chassis ground
ness 1) Turn the starting switch OFF.
5
(Disconnection or defective 2) Disconnect connectors R03, BT3, and PSW.
contact) 3) Connect T-adapter.
Wiring harness between fuse BT3 (16) PSW
Resistance Max. 1 z
(female) (1)
Resistance Max. 1 z
PSW (female) (2)
and standard value 2) Disconnect connectors BRC5A and R03.
in normal state Ground fault of wiring har- 3) Connect T-adapter.
6
ness
Between BRC5A (female), R03 (female) (3)
chassis ground
2) Disconnect connector BRC5A.
4) Connect connector BRC5A
7 Retarder controller defective Set parking brake
switch in FREE posi- Voltage Max. 1 V
Between BRC5A (5) tion.
chassis ground Set parking brake
switch in PARK posi- Voltage 20 30 V
tion.
20-536 HD465-7, HD605-7

(10)
TROUBLESHOOTING [989A00]
[989A00] ENGINE OVERRUN PREVENTION COMMAND SIGNAL: OPERATION (00)

Trouble Engine overrun prevention command signal: Operation (00)
E02 989A00 TM
When the gear speed is not in neutral, the transmission input shaft speed signal rises higher than 2,600
Contents of trouble
rpm.
Action of controller The controller sends a command signal to the retarder controller to apply the brake.
Problem that
The brake operates and the travel speed lowers.
appears on machine

aIf the machine is traveling under the condition where the transmission
Possible causes 1 Overrun of engine input shaft speed signal rises higher than 2,600 rpm, the engine is
and standard value overrunning.
in normal state If the machine is not traveling under the condition where the transmis-
2 sion input shaft speed signal rises higher than 2,600 rpm, the trans-
fective
mission controller is defective.
HD465-7, HD605-7 20-537

(10)
TROUBLESHOOTING [989AKZ]
[989AKZ] ENGINE OVERRUN PREVENTION COMMAND SIGNAL: DISCONNECTION

OR SHORT CIRCUIT (KZ)
Action code Failure code Controller code Engine overrun prevention command signal: Disconnection or
Trouble
E01 989AKZ TM short circuit (KZ)
There is disconnection, grounding fault, or short circuit with power source in the engine overrun pre-
Contents of trouble
vention command signal circuit.
Action of controller The controller continues the control with the S-NET signal.
Problem that
This failure does not have a serious effect on the machine.
appears on machine
Related information None in particular.

2) Disconnect connectors ATC1 and BRC5B.
ness
1 Wiring harness between ATC1 (female) (13)
BRC5B (female) (5)
contact)
Wiring harness between fuse BT3 Voltage between ATC1
20 30 V
terminal (14) ATC1 (female) (4) (4) chassis ground
2) Disconnect connectors ATC1 BRC5B.
Ground fault of wiring har-
2 Resistance between
ness
Wiring harness between ATC1 (fe- ATC1 (female) (13),
Min. 1 Mz
male) (13) BRC5B (female) (5) BRC5B (female) (5)
chassis ground
and standard value 2) Disconnect connectors ATC1 BRC5B.
in normal state 3) Connect T-adapter.
3 Hot short in wiring harness Voltage between ATC1
Wiring harness between ATC1
(female) (13), BRC5B
(female) (13) BRC5B (female) Max. 1 V
(female) (5) chassis
(5)
ground
2) Disconnect connector BRC5B.
4 Retarder controller defective 4) Connect the connector.
Between BRC5B (5) chassis ground Voltage Max. 1 V
5 4) Connect the connector.
fective
Between ATC1 (13) chassis ground Voltage Max. 1 V
20-538 HD465-7, HD605-7

(10)
TROUBLESHOOTING [AA10NX]
[AA10NX] AIR CLEANER ELEMENT: CLOGGING (NX)

Trouble Air cleaner element: Clogging (NX)
E01 AA10NX TM
Contents of trouble The air cleaner clogging signal circuit is opened (disconnected from GND).
Problem that
If the machine is used without repairing, the suction performance of the engine may be lowered.
appears on machine

The dust indicator is not red. Air cleaner is normal.
1 Clogging of air cleaner
The dust indicator is red. Air cleaner is clogged.
Relay (R32)
No
When the dust indicator relay (R32) is re- is normal.
placed, is failure repaired? Relay (R32)
Yes
is defective.
Dust indicator relay (R32) 3) Check the relay.
2
defective
3) Check the relay.
Apply 24 V between
Resistance Max. 1 z
tween (1) (2).
Possible causes
2) Disconnect connectors FR01.
and standard value Air cleaner clogging sensor 3) Connect T-adapter.
in normal state 3
defective
Between FR01 (male) Air cleaner is normal. Resistance Max. 1 z
(1) (2) Air cleaner is clogged. Resistance Min. 1 Mz
2) Disconnect connectors ATC3A and R32.
ness
4 Wiring harness between ATC3A (female) (16)
R32 (female) (6)
contact)
Wiring harness between ATC3A (female) (19)
Resistance Max. 1 z
R32 (female) (3)
2) Disconnect connector R32 and FR01.
Ground fault of wiring har-
ness
Wiring harness between R32 R32 (female) (2),
Min. 1 Mz
(female) (2) FR01 (female) (1) FR01 (female) (1)
chassis ground
2) Disconnect connectors ATC3A.
Transmission controller de- 4) Connect connector.
6
Between ATC3A (19) Air cleaner is normal. Voltage 20 30 V
(16) Air cleaner is clogged. Voltage Max. 1 V
HD465-7, HD605-7 20-539

(10)
TROUBLESHOOTING [AA10NX]
20-540 HD465-7, HD605-7

(1)
TROUBLESHOOTING [AB00MA]
[AB00MA] ALTERNATOR: MALFUNCTION (MA)
Action code Failure code Controller code Alternator: Malfunction (MA)

Trouble
E03 AB00MA TM (Failure in battery charging circuit)
Contents of trouble A generation signal is not input from the alternator while the engine is running.
Problem that If the machine is used without repairing, the source voltage may lower so much that the machine cannot
appears on machine travel.

2) Disconnect connector alternator terminal R.
1 Alternator defective
Between alternator R E Voltage 20 30 V
aIf the battery is deteriorated or used in a cold district, the voltage may
not rise for a while after the engine is started.
2) Disconnect connector ATC3B.
Disconnection in wiring har- Wiring harness between Voltage between ATC3B (fe-
20 30 V
Possible causes ness ATC3B (female) (1) alter- male) (1) chassis ground
and standard value 2 (Disconnection or defective nator terminal R Resistance Max. 1 z
in normal state contact) aIf the battery is deteriorated or used in a cold district, the voltage may
Wiring harness between battery relay terminal
Resistance Max. 1 z
M alternator terminal R
3 5) Start the engine.
fective
Between ATC3B (1) chassis ground Voltage 20 30 V
aIf the battery is deteriorated or used in a cold district, the voltage may
HD465-7, HD605-7 20-541

(10)
TROUBLESHOOTING [AB00MA]
20-542 HD465-7, HD605-7

(1)
TROUBLESHOOTING [B@BCZK]
[B@BCZK] LOWERING OF RADIATOR WATER: LOWERING OF LEVEL (ZK)

Trouble Lowering of radiator coolant: Lowering of level (ZK)
E01 B@BCZK TM
Contents of trouble The radiator coolant level switch signal circuit is opened (disconnected from GND).
Problem that
If the machine is used without repairing, the engine may overheat.
appears on machine

The radiator coolant level is normal.
Lowering of radiator coolant
1
level aIf the radiator coolant level is low, check around the engine and ra-
diator for coolant leakage before adding coolant .
2) Disconnect connector FL01.
Radiator coolant level
2 Radiator coolant level
switch defective Resistance Max. 1 z
Between FL01 (male) is normal.
(1) (2) Radiator coolant level
is low.
Possible causes 2) Disconnect connectors ATC5A and FL01.
and standard value Disconnection in wiring har- 3) Connect T-adapter.
in normal state ness
FL01 (female) (1)
contact)
Wiring harness between FL01 (female) (2)
Resistance Max. 1 z
chassis ground
Transmission controller de- 5) Turn the starting switch ON.
3
fective
Radiator coolant level
Between ATC5A (fe- is normal. Voltage Max. 1 V
male) (3) chassis
ground Radiator coolant level
Voltage 20 30 V
is low.
HD465-7, HD605-7 20-543

(10)
TROUBLESHOOTING [D1B0KZ]
[D1B0KZ] TRANSMISSION CONTROLLER CUTOUT: DISCONNECTION OR SHORT

CIRCUIT (KZ)
Action code Failure code Controller code Transmission controller cutout relay: Disconnection or short cir-
Trouble cuit (KZ)
E03 D1B0KZ TM (Disconnection or short circuit)
Contents of trouble Abnormal voltage is generated in the transmission cutout relay circuit.
The controller turns the transmission cutout relay OFF.
The controller sets the gear in Neutral.
Problem that
appears on machine

Relay (R15)
No
When transmission cutout relay (R15) is is normal.
replaced, is failure repaired? Relay (R15)
Yes
is defective.
Transmission controller cut- 3) Check the relay.
1
out relay (R15) defective
3) Check the relay.
Apply 24 V between
Resistance Max. 1 z
between (1) (2).
and standard value 2) Disconnect connectors ATC1 and R15.
ness Wiring harness between ATC1 (female) (14)
2 Resistance Max. 1 z
(Disconnection or defective R15 (female) (1)
contact) Between R15 (female) (2) chassis ground Resistance Max. 1 z
Wiring harness between fuse BT2 Voltage between ATC1
20 30 V
terminal (22) ATC1 (female) (5) (5) chassis ground
2) Disconnect connectors ATC1 and R15.
Ground fault in wiring har-
ness
Min. 1 Mz
male) (14) R15 (female) (1) R15 (female) (1)
chassis ground
4
fective When failure code to turn transmis-
Between sion cutout relay OFF is displayed Voltage Max. 1 V
ATC1 (14) (Example: 1500LO)
(8), (16)
When failure code is not displayed Voltage 20 30 V
20-544 HD465-7, HD605-7

(10)
TROUBLESHOOTING [D1BOKZ]
HD465-7, HD605-7 20-545

(1)
TROUBLESHOOTING [D5ZMKZ]
[D5ZMKZ] DISCONNECTION, GROUNDING FAULT, OR SHORT CIRCUIT IN ENGINE

OUTPUT MODE COMMAND LINE: DISCONNECTION OR SHORT CIRCUIT
(KZ)
Action code Failure code Controller code Disconnection, grounding fault, or short circuit in engine output
Trouble
E01 D5ZMKZ TM mode command line: Disconnection or short circuit (KZ)
Contents of trouble Disconnection, grounding fault, or short circuit occurs in engine output mode command line.
Action of controller The controller controls in the power mode (The machine is fixed to the power mode).
Problem that
appears on machine

Disconnection in wiring har- 2) Disconnect connectors ATC1 ECMB.
1
ECMB (female) (19)
2) Disconnect connectors ATC1 and ECMB.
2
ness Wiring harness between Resistance between ATC1
ATC1 (female) (15) ECMB (female) (15), ECMB (fe- Min. 1 Mz
(female) (19) male) (19) chassis ground
2) Disconnect connectors ATC5A and BRC5B.
3 Hot short in wiring harness 3) Connect T-adapter.
Possible causes
and standard value Between ATC1 (female) (15), ECMB (female)
Voltage Max. 1 V
in normal state (19) chassis ground
Between ECMB (19) In power mode Voltage 9.4 12 V
chassis ground In economy mode Voltage 0 2.4 V
Transmission controller de- 4) Disconnect the connector.
5
fective 5) Start the engine.
Between ATC1 (15) In power mode Voltage 9.4 12 V
chassis ground
In economy mode Voltage 0 2.4 V
20-546 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DAQ0KK]
[DAQ0KK] TRANSMISSION CONTROLLER: LOWERING OF SOURCE/INPUT VOLTAGE

(KK)

Trouble Transmission controller: Lowering of source/input voltage (KK)
E03 DAQ0KK TM
While the engine is running, the voltages of both main power source voltage circuit and direct power
Contents of trouble
source voltage circuit lower below 18 V.
Problem that The gear is set in Neutral suddenly during travel and the machine cannot start again until the voltage
appears on machine rises to the normal level.
If failure code "ABOOMA" (Malfunction of alternator) is indicated, perform troubleshooting for it first.
Related information If the fuse is broken, check the line between the fuse and BRC1 (female) (7), (9), and (17) for grounding
fault.

1) Test the battery voltage and specific gravity of the battery fluid.
Battery voltage Voltage Min. 24 V
1 Battery defective
Specific
Specific gravity of battery fluid Min. 1.26
gravity
Wiring harness between ATC1 (female) (8),
Resistance Max. 1 z
(16) chassis ground
ness 4) Connect the connector.
2
(Disconnection or defective Wiring harness between battery, Voltage between ATC1
contact) 20 30 V
Possible causes battery relay terminal B, ATC1 (7) (7) (8), (16)
in normal state 2) Disconnect connector ATC1.
Wiring harness between battery re- Voltage between ATC1
20 30 V
lay terminal M ATC1 (9), (17) (9), (17) (8), (16)
2) Disconnect connector ATC1
Between ATC1 (7) (8), (16) Voltage 20 30 V
3 1) Turn the starting switch OFF.
fective
2) Disconnect connector ATC1
Between ATC1 (9), (17) (8), (16) Voltage 20 30 V
HD465-7, HD605-7 20-547

(10)
20-548 HD465-7, HD605-7

(1)
[DAQ1KK] MAIN POWER LINE OF TRANSMISSION CONTROLLER: LOWERING OF

SOURCE/INPUT VOLTAGE (KK)
Action code Failure code Controller code Main power line of transmission controller: Lowering of source/in-
Trouble
E03 DAQ1KK TM put voltage (KK)
Contents of trouble The main power source voltage is lower than the direct power source voltage by 5 V or more.
Action of controller The controller prohibits updating of information about input.
Problem that
The condition before the failure is kept.
appears on machine
Related information If the fuse is broken, check the line between the fuse ATC1 (female) (9) and (17) for grounding fault.

Resistance Max. 1 z
(16) chassis ground
Disconnection in wiring har- 4) Connect the connector.
ness
1
(Disconnection or defective Wiring harness between battery Voltage between bat-
contact) tery relay terminal B 20 30 V
Possible causes battery relay terminal B
chassis ground
and standard value
Wiring harness between battery re- Voltage between ATC1
20 30 V
lay terminal M ATC1 (9), (17) (9), (17) (8), (16)
Transmission controller de- 3) Insert T-adapter.
fective
Between ATC1 (9), (17) (8), (16) Voltage 20 30 V
HD465-7, HD605-7 20-549

(10)
20-550 HD465-7, HD605-7

(1)
[DAQ2KK] TRANSMISSION CONTROLLER LOAD POWER LINE: LOWERING OF

Action code Failure code Controller code Transmission controller load power line: Lowering of source/input
Trouble
E03 DAQ2KK TM voltage (KK)
Contents of trouble While the transmission controller source voltage is normal, the solenoid source voltage is below 18 V.
The controller sets the gear in Neutral.
Problem that
appears on machine
Related information If the fuse is broken, check the line between the fuse and ATC1 (female) (9) and (17) for grounding fault.

3) Turn the starting switch ON
Relay (R15)
No
When transmission cutout relay (R15) is re- is normal.
placed, is failure repaired? Relay (R15)
Yes
is defective.
Transmission controller cut- 3) Check the relay.
1
out relay (R15) defective
3) Check the relay.
Apply 24 V between
Resistance Max. 1 z
Possible causes
and standard value (3) (5) Do not apply voltage
in normal state between (1) (2).
2) Disconnect connectors R15.
Disconnection in wiring har- Wiring harness between fuse BT3 Voltage between R15
ness (female) (3) chassis 20 30 V
2 to 14 R15 (female) (3)
(Disconnection or defective ground
contact) 1) Turn the starting switch OFF.
2) Disconnect connectors ATC2 and R15.
Wiring harness between ATC2 (1), (12) R15
Resistance Max. 1 z
(female) (3)
fective
Between ATC2 (1), (12) chassis ground Voltage 20 30 V
HD465-7, HD605-7 20-551

(10)
20-552 HD465-7, HD605-7

(1)
[DAQ3KK] DIRECT LINE OF TRANSMISSION CONTROLLER BATTERY: LOWERING

OF SOURCE/INPUT VOLTAGE (KK)
Action code Failure code Controller code Direct line of transmission controller battery: Lowering of source/
Trouble
E03 DAQ3KK TM input voltage (KK)
Contents of trouble The direct power source voltage is below 5 V.
Problem that
appears on machine
Related information If the fuse is broken, check the line between the fuse and ATC1 (female) (7) for grounding fault.

Disconnection in wiring har- (16) chassis ground Resistance Max. 1 z
ness
1
(Disconnection or defective 1) Turn the starting switch OFF.
contact) 2) Disconnect connector ATC1.
Possible causes
and standard value
in normal state
Wiring harness between battery, Voltage between ATC1
20 30 V
battery relay terminal B, ATC1 (7) (7) (8), (16)
fective
Between ATC1 (7) (8), (16) Voltage 20 30 V
HD465-7, HD605-7 20-553

(10)
TROUBLESHOOTING [DAQ9KM]
[DAQ9KM] TRANSMISSION CONTROLLER WIRING HARNESS: MISTAKE IN

OPERATION OR SETTING (KM)
Action code Failure code Controller code Transmission controller wiring harness: Mistake in operation or
Trouble
E03 DAQ9KM TM setting (KM)
The connector check signal, that is input when the starting switch is turned to the ON position, does not
Contents of trouble
agree with setting in the controller.
Action of controller The controller keeps the gear speed in neutral.
This failure is not recorded in the fault history.
Problem that
When the starting operation is performed, the machine does not start.
appears on machine

The connector of the connector check signal is connected normally.
Wrong connection of con-
1 aConnector check signal connector: ATC3A (1) (OPEN), ATC5A (1)
nector
(CLOSE)
Disconnection in wiring har- 2) Disconnect connector ATC5A.
2
chassis ground
and standard value 2) Disconnect connector ATC3A.
in normal state Ground fault in wiring har- 3) Connect T-adapter.
3
ness Resistance between
Wiring harness between ATC3A
ATC3A (female) (1) Min. 1 Mz
chassis ground
4
fective Wiring harness between ATC5A (female) (1)
Resistance Max. 1 z
chassis ground
Between ATC3A (female) (1) chassis ground Resistance Min. 1 Mz
20-554 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DAQ9KQ]
[DAQ9KQ] TRANSMISSION CONTROLLER WIRING HARNESS: DISAGREEMENT OF

MODEL SELECTION SIGNALS (KQ)
Action code Failure code Controller code Transmission controller wiring harness: Disagreement of model
Trouble
E03 DAQ9KQ TM selection signals (KQ)
The model selection signal input when the starting switch is turned ON is different from the setting of
Contents of trouble
the controller.
Action of controller The controller sets the gear speed in neutral.
Problem that
appears on machine

ness
chassis ground
contact)
Resistance Max. 1 z
chassis ground
Possible causes 3) Connect T-adapter.
and standard value 2 ness Resistance between
in normal state Wiring harness between ATC5A ATC5A (female) (15),
Min. 1 Mz
(female) (15) MS21 (female) MS21 (female) chas-
sis ground
Wrong setting of rotary For setting of the rotary switch, see ADJUSTING TRANSMISSION
3
switch CONTROLLER.
Wrong setting of rotary
4 Between ATC5A (female) (14) chassis ground Resistance Max. 1 z
switch
Between ATC5A (female) (15) chassis ground Resistance Min. 1 Mz
Between ATC5A (female) (16) chassis ground Resistance Max. 1 z
HD465-7, HD605-7 20-555

(10)
TROUBLESHOOTING [DAQAKQ], [DAQSMA]
[DAQAKQ] TRANSMISSION CONTROLLER ROTARY SWITCH: DISAGREEMENT OF

Action code Failure code Controller code Transmission controller wiring harness: Disagreement of model
Trouble
E03 DAQAKQ TM selection signals (KQ)
Contents of trouble Setting of the model by the rotary switch does not agree with setting in the controller.
Action of controller The controller sets the gear speed in neutral.
Problem that
appears on machine

Wrong setting of rotary For setting of the rotary switch, see ADJUSTING TRANSMISSION
Possible causes 1
switch CONTROLLER.
and standard value
in normal state For setting of the rotary switch, see ADJUSTING TRANSMISSION
2 CONTROLLER.
fective
aIf setting is normal, the transmission controller is defective.
[DAQSMA] TRANSMISSION CONTROLLER: MALFUNCTION (MA)

Trouble Transmission controller: Malfunction (MA)
E03 DAQSMA TM
Contents of trouble Communication with the machine monitor (S-NET) is defective and the optional items cannot be set.
Action of controller The controller sets the gear speed in Neutral.
Problem that
appears on machine
If failure code "DAQSKR" of the machine monitor system is indicated, perform troubleshooting for it
first.
Related information
Do not turn the starting switch to the left before starting the engine (Since the engine preheating system
is automatic, the starting switch does not need to be turned to the left).

Possible causes aIf the failure is not repaired by replacing the transmission controller,
1 Machine monitor defective
and standard value the machine monitor is defective.
in normal state Transmission controller de- aIf the failure is repaired by replacing the transmission controller, the
2
fective transmission controller is defective.
20-556 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DDTGKA]
[DDTGKA] LOCKUP CLUTCH FILL SWITCH: DISCONNECTION (KA)
Action code Failure code Controller code Lockup clutch fill switch: Disconnection (KA)
Trouble (Command is Holding pressure, fill switch is OFF, and slip is not
E03 DDTGKA TM sensed)
When the output to the lockup clutch ECMV is turned ON, the clutch is engaged but the signal from the
Contents of trouble
fill switch is not turned ON.
The controller keeps the current gear speed.
The gear cannot be shifted.
Problem that
If the shift lever is set in the "N" position, the machine cannot start until it is stopped.
appears on machine
The lockup pilot lamp does not light up.

Lockup clutch fill switch de-
1 When dis-
sis ground When en-
Resistance Max. 1 z
gaged
Possible causes Disconnection in wiring har- 2) Disconnect connectors ATC5A and CN21.
2 3) Connect T-adapter.
in normal state (Disconnection or defective
CN21 (female) (1)
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-557

(10)
TROUBLESHOOTING [DDTHKA]
[DDTHKA] HI CLUTCH FILL SWITCH: DISCONNECTION (KA)
Action code Failure code Controller code Hi clutch fill switch: Disconnection (KA)
E03 DDTHKA TM sensed)
When the output to the Hi clutch ECMV is turned ON, the clutch is engaged but the signal from the fill
Contents of trouble
switch is not turned ON.
Problem that The gear cannot be shifted.

1 Hi clutch fill switch defective When dis-
sis ground When en-
Resistance Max. 1 z
gaged

Disconnection in wiring har- 2) Disconnect connectors ATC5A and CN19.
CN19 (female) (1)
3 When dis-
Resistance Max. 1 z
gaged
20-558 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DDTJKA]
[DDTJKA] LO CLUTCH FILL SWITCH: DISCONNECTION (KA)
Action code Failure code Controller code Lo clutch fill switch: Disconnection (KA)
E03 DDTJKA TM sensed)
When the output to the Lo clutch ECMV is turned ON, the clutch is engaged but the signal from the fill
Contents of trouble

1 Lo clutch fill switch defective When dis-
sis ground When en-
Resistance Max. 1 z
gaged

Disconnection in wiring har- 2) Disconnect connectors ATC5A and CN17.
CN17 (female) (1)
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-559

(10)
TROUBLESHOOTING [DDTKKA]
[DDTKKA] 1ST CLUTCH FILL SWITCH: DISCONNECTION (KA)
Action code Failure code Controller code 1st clutch fill switch: Disconnection (KA)
E03 DDTKKA TM sensed)
When the output to the 1st clutch ECMV is turned ON, the clutch is engaged but the signal from the fill
Contents of trouble

1 1st clutch fill switch defective When dis-
ground When en-
Resistance Max. 1 z
gaged
CN7 (female) (1)
3 When dis-
Resistance Max. 1 z
gaged
20-560 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DDTLKA]
[DDTLKA] 2ND CLUTCH FILL SWITCH: DISCONNECTION (KA)
Action code Failure code Controller code 2nd clutch fill switch: Disconnection (KA)
E03 DDTLKA TM sensed)
When the output to the 2nd clutch ECMV is turned ON, the clutch is engaged but the signal from the
Contents of trouble
fill switch is not turned ON.

2nd clutch fill switch defec-
1 When dis-
ground When en-
Resistance Max. 1 z
gaged
CN9 (female) (1)
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-561

(10)
TROUBLESHOOTING [DDTMKA]
[DDTMKA] 3RD CLUTCH FILL SWITCH: DISCONNECTION (KA)
Action code Failure code Controller code 3rd clutch fill switch: Disconnection (KA)
E03 DDTMKA TM sensed)
When the output to the 3rd clutch ECMV is turned ON, the clutch is engaged but the signal from the fill
Contents of trouble

3rd clutch fill switch defec-
1 When dis-
sis ground When en-
Resistance Max. 1 z
gaged
CN13 (female) (1)
3 When dis-
Resistance Max. 1 z
gaged
20-562 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DDTNKA]
[DDTNKA] R CLUTCH FILL SWITCH: DISCONNECTION (KA)
Action code Failure code Controller code R clutch fill switch: Disconnection (KA)
E03 DDTNKA TM sensed)
When the output to the R clutch ECMV is turned ON, the clutch is engaged but the signal from the fill
Contents of trouble

1 R clutch fill switch defective When dis-
sis ground When en-
Resistance Max. 1 z
gaged
CN11 (female) (1)
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-563

(10)
TROUBLESHOOTING [DDTPKA]
[DDTPKA] 4TH CLUTCH FILL SWITCH : DISCONNECTION (KA)
Action code Failure code Controller code 4th clutch fill switch : Disconnection (KA)
E03 DDTPKA TM sensed)
When the output to the 4th clutch ECMV is turned ON, the clutch is engaged but the signal from the fill
Contents of trouble

4th clutch fill switch defec-
1 When dis-
sis ground When en-
Resistance Max. 1 z
gaged
CN15 (female) (1)
3 When dis-
Resistance Max. 1 z
gaged
20-564 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DF10KA]
[DF10KA] SHIFT LEVER: DISCONNECTION (KA)

Trouble Shift lever: Disconnection (KA)
E03 DF10KA TM
Contents of trouble The shift lever signal is not input at all.
Action of controller The controller keeps the condition before occurrence of the failure..
The gear may be shifted up above the gear speed set with the shift lever.
Problem that The gear is kept in neutral and the machine cannot start.
appears on machine The travel direction cannot be changed.
All the shift lever position lamps go off.

The shift lever is pressed by some force while it is not operated.
1 Wrong operation
The shift lever is stopped between 2 positions.
2) Disconnect connector SF1.
Wiring harness between BT3 (10) SF1 (fe-
Resistance Max. 1 z
male) (1)
2) Disconnect connectors ATC5B and SF1.
Wiring harness between ATC5B (female) (2)
Resistance Max. 1 z
SF1 (female) (3)
Resistance Max. 1 z
Disconnection in wiring har- SF1 (female) (4)
ness Wiring harness between ATC5B (female) (4)
2 (Disconnection or defective SF1 (female) (5) Resistance Max. 1 z
contact of connector)
Resistance Max. 1 z
SF1 (female) (6)
Resistance Max. 1 z
Possible causes SF1 (female) (7)
and standard value Wiring harness between ATC5B (female) (7)
SF1 (female) (8)
Resistance Max. 1 z
SF1 (female) (9)
Resistance Max. 1 z
SF1 (female) (10)
Resistance Max. 1 z
SF1 (female) (11)
Resistance between
Wiring harness between ATC5B ATC5B (female) (2),
Min. 1 Mz
(female) (2) SF1 (female) (3) SF1 (female) (3)
chassis ground
3 Hot short in wiring harness Resistance between
Min. 1 Mz
chassis ground
Resistance between
Min. 1 Mz
chassis ground
HD465-7, HD605-7 20-565

(10)

Resistance between
Min. 1 Mz
chassis ground
Resistance between
Min. 1 Mz
chassis ground
Resistance between
Min. 1 Mz
chassis ground
Resistance between
Min. 1 Mz
chassis ground
Resistance between
Min. 1 Mz
chassis ground
Resistance between
Min. 1 Mz
chassis ground
and standard value When shift range is "R" Voltage 20 30 V
in normal state Between SF1 (3)
chassis ground When shift range is not
Voltage Max. 1 V
"R"
When shift range is "N" Voltage 20 30 V
Between SF1 (4)
Voltage Max. 1 V
"N"
When shift range is "D" Voltage 20 30 V
Between SF1 (5)
Voltage Max. 1 V
"D"
When shift range is "6" Voltage 20 30 V
Between SF1 (6)
4 Gearshift lever defective Voltage Max. 1 V
"6"
Between SF1 (7)
Voltage Max. 1 V
"5"
Between SF1 (8)
Voltage Max. 1 V
"4"
Between SF1 (9)
Voltage Max. 1 V
"3"
Between SF1 (10)
Voltage Max. 1 V
"2"
Between SF1 (11)
Voltage Max. 1 V
"1"
20-566 HD465-7, HD605-7

(10)

When shift range is "R" Voltage 20 30 V
Between ATC5B (2)
Voltage Max. 1 V
"R"
Between ATC5B (3)
Voltage Max. 1 V
"N"
Between ATC5B (4)
When shift range is not
chassis ground Voltage Max. 1 z
"D"
Possible causes Between ATC5B (5)
and standard value Transmission controller de- chassis ground When shift range is not
5 Voltage Max. 1 V
in normal state fective "6"
Between ATC5B (6)
Voltage Max. 1 V
"5"
Between ATC5B (7)
Voltage Max. 1 V
"4"
Between ATC5B (8)
Voltage Max. 1 V
"3"
Between ATC5B (9)
Voltage Max. 1 V
"2"
Between ATC5B (10)
Voltage Max. 1 V
"1"
HD465-7, HD605-7 20-567

(10)
20-568 HD465-7, HD605-7

(1)
TROUBLESHOOTING [DF10KB]
[DF10KB] SHIFT LEVER: SHORT CIRCUIT (KB)

Trouble Shift lever: Short circuit (KB)
E03 DF10KB TM
Contents of trouble The shift lever signals are input from 2 or more systems.
The controller controls with the signal having higher priority.
(1): N > D > 6 > 5 > 4 > 3 > 2 > 1.
(2): N > R
If the signals of systems (1) and (2) are input simultaneously, the controller sets the gear in neutral.
The gear may be shifted up above the gear speed set with the shift lever.
Problem that
The gear is kept in neutral and the machine cannot start.
appears on machine
The shift lever position lamp is different from the shift lever position.

Voltage between
Max. 1 V
chassis ground
Voltage between
Max. 1 V
chassis ground
Voltage between
Max. 1 V
chassis ground
Voltage between
Max. 1 V
Possible causes
Short circuit in wiring har- chassis ground
and standard value
in normal state 1 ness Voltage between
(Hot short in wiring harness) Wiring harness between ATC5B ATC5B (female) (6),
Max. 1 V
chassis ground
Voltage between
Max. 1 V
chassis ground
Voltage between
Max. 1 V
chassis ground
Voltage between
Max. 1 V
chassis ground
Voltage between
Max. 1 V
chassis ground
HD465-7, HD605-7 20-569

(10)

Between SF1 (3)
Voltage Max. 1 V
"R"
Between SF1 (4)
Voltage Max. 1 V
"N"
Between SF1 (5) When shift range is "D" Voltage 20 30 V
Voltage Max. 1 z
"D"
Between SF1 (6)
2 Gearshift lever defective Voltage Max. 1 V
"6"
Between SF1 (7)
Voltage Max. 1 V
"5"
Between SF1 (8) When shift range is "4" Voltage 20 30 V
Voltage Max. 1 V
"4"
Between SF1 (9)
Possible causes Voltage Max. 1 V
"3"
and standard value
in normal state Between SF1 (10)
Voltage Max. 1 V
"2"
Between SF1 (11)
Voltage Max. 1 V
"1"
When the right FNR switch is installed (Turn the right FNR switch ON)
Between ATC5B (2)
Voltage Max. 1 V
"R"
Transmission controller de- Between ATC5B (3) When shift range is not
3 chassis ground Voltage Max. 1 V
fective "N"
Between ATC5B (4)
Voltage Max. 1 V
"D"
Between ATC5B (5) When shift range is "6" Voltage 20 30 V
Voltage Max. 1 z
"6"
Between ATC5B (6)
Voltage Max. 1 V
"5"
20-570 HD465-7, HD605-7

(10)

Between ATC5B (7)
Voltage Max. 1 V
"4"
Between ATC5B (8) When shift range is "3" Voltage 20 30 V
Possible causes chassis ground When shift range is not
Transmission controller de- Voltage Max. 1 V
and standard value "3"
in normal state 3 fective
Between ATC5B (9)
Voltage Max. 1 V
"2"
Between ATC5B (10)
Voltage Max. 1 V
"1"
HD465-7, HD605-7 20-571

(10)
TROUBLESHOOTING [DGF1KX]
[DGF1KX] TRANSMISSION VALVE OIL TEMPERATURE SENSOR: OUT OF INPUT

SIGNAL RANGE (KX)
Action code Failure code Controller code Transmission valve oil temperature sensor: Out of input signal
Trouble
E03 DGF1KX TM range (KX)
The voltage of the signal circuit of the transmission valve oil temperature sensor is below 0.97 V (above
Contents of trouble
150C) or very different from the torque converter oil temperature signal.
Action of controller The controller controls the clutch oil pressure, fixing the sensed oil temperature high.
Problem that
Gear shift shocks become large.
appears on machine
Related information After repairing the failure and confirming resetting of the machine, perform the initial learning of the
transmission controller, referring to TESTING AND ADJUSTING, "Inspection of machine monitor".

Transmission oil tempera- 3) Connect T-adapter.
1
ture sensor defective
Between CN24 (male) Oil temperature: 25C Resistance 37 50 kz
(1) (2) Oil temperature: 100C Resistance 3.5 4.0 kz
2) Disconnect connectors ATC3A, ATC3B, and CN24.
ness
2 Wiring harness between ATC3B (female) (9)
CN24 (female) (2)
contact)
Resistance Max. 1 z
CN24 (female) (1)
2) Disconnect connectors ATC3B and CN24.
Possible causes 3 Resistance between
ness
and standard value Wiring harness between ATC3B ATC3B (female) (9),
in normal state Min. 1 Mz
chassis ground
Voltage between
Max. 1 V
chassis ground
2) Disconnect connectors ATC3A and ATC3B.
5 5) Turn the starting switch ON.
fective
Between ATC3B (fe- Oil temperature: 25C Resistance 37 50 kz
male) (9) ATC3A (fe-
male) (16) Oil temperature: 100C Resistance 3.5 4.0 kz
20-572 HD465-7, HD605-7

(10)
TROUBLESHOOTING [GDF1KX]
HD465-7, HD605-7 20-573

(1)
TROUBLESHOOTING [DGT1KX]
[DGT1KX] TORQUE CONVERTER OIL TEMPERATURE SENSOR: OUT OF

INPUTSIGNAL RANGE (KX)
Action code Failure code Controller code Torque converter oil temperature sensor: Out of input signal
Trouble
E01 DGT1KX TM range (KX)
The voltage of the signal circuit of the torque converter oil temperature sensor is below 0.97 V (above
Contents of trouble
150C) or very different from the transmission valve oil temperature signal.
Problem that
The torque converter oil temperature gauge does not indicate normally.
appears on machine

Torque converter oil temper- 3) Connect T-adapter.
1
ature sensor defective
Between CN23 (T/C-T) Oil temperature: 25C Resistance 37 50 kz
(male) (1) (2) Oil temperature: 100C Resistance 3.5 4.0 kz
2) Disconnect connectors ATC3A, ATC3B, and CN23.
ness
2 Wiring harness between ATC3B (female) (7)
TC-SE (female) (2)
contact)
Resistance Max. 1 z
CN23 (female) (1)
Possible causes Ground fault in wiring har-
in normal state Min. 1 Mz
chassis ground
Voltage between
Max. 1 V
chassis ground
2) Disconnect connectors ATC3A and ATC3B.
5 5) Turn the starting switch ON.
fective
Between ATC3B (fe- Oil temperature: 25C Resistance 37 50 kz
male) (7) ATC3A (fe-
male) (16) Oil temperature: 100C Resistance 3.5 4.0 kz
20-574 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DHT5KX]
[DHT5KX] TORQUE CONVERTER OIL PRESSURE SENSOR: OUT OF INPUT SIGNAL

RANGE (KX)
Action code Failure code Controller code Torque converter oil pressure sensor: Out of input signal range
Trouble
E01 DHT5KX TM (KX)
The voltage of the signal circuit of the torque converter oil pressure sensor is below 0.5 V or above 4.5
Contents of trouble
V.
Action of controller The controller controls the machine, fixing the torque converter oil pressure to the set pressure in itself.
Problem that
Large shocks are made when the lockup system is operated.
appears on machine

2) Disconnect connectors ATC1, ATC3A and CN22.
Disconnection in wiring har- Wiring harness between ATC3A (female) (7)
1 CN22 (female) (C)
CN22 (female) (A)
Resistance Max. 1 z
CN22 (female) (B)
Resistance between
Ground fault in wiring har- Min. 1 Mz
2 (female) (7) CN22 (female) (C) CN22 (female) (C)
ness
chassis ground
Resistance between
Min. 1 Mz
male) (3) CN22 (female) (B) CN22 (female) (B)
Possible causes chassis ground
in normal state 2) Disconnect connectors ATC3B and CN22.
Voltage between
0.8 2.0 V
(female) (7) CN22 (female) (C) CN22 (female) (C)
chassis ground
Torque converter oil pres- 4) Connect the connector.
4
sure sensor defective 5) Turn the starting switch ON.
Between CN22 (B) (A) Voltage 20 30 V
Between CN22 (C) (A) Voltage 0.8 2.0 V
2) Disconnect connectors ATC1 and ATC3A.
5
Between ATC1 (3) ATC3A (17) Voltage 20 30 V
Between ATC3A (7) (17) Voltage 0.8 2.0 V
HD465-7, HD605-7 20-575

(10)
TROUBLESHOOTING [DHT5KX]
20-576 HD465-7, HD605-7

(1)
TROUBLESHOOTING [DHT5L6]
[DHT5L6] TORQUE CONVERTER OIL PRESSURE SENSOR: *SEE SEPARATE LIST

(L6)

Trouble Torque converter oil pressure sensor: *See separate list (L6)
E01 DHT5L6 TM
While the engine is stopped, an oil pressure signal is input to the signal circuit of the torque converter
Contents of trouble
oil pressure sensor.
Action of controller The controller controls the machine, fixing the torque converter oil pressure to the set pressure in itself.
Problem that
Large shocks are made when the lockup system is operated.
appears on machine

Voltage between
Max. 1.2 V
(female) (7) CN22 (female) (C) CN22 (female) (C)
chassis ground
Possible causes 2) Disconnect connector CN22.
and standard value 3) Insert T-adapter.
Torque converter oil pres- 4) Connect the connector.
in normal state 2
Between CN22 (B) (A) Voltage 20 30 V
Between CN22 (C) (A) Voltage 0.8 2.0 V
3
Between ATC1 (3) ATC3A (17) Voltage 20 30 V
HD465-7, HD605-7 20-577

(10)
TROUBLESHOOTING [DJF1KA]
[DJF1KA] FUEL LEVEL SENSOR: DISCONNECTION (KA)

Trouble Fuel level sensor: Disconnection (KA)
E01 DJF1KA TM
Contents of trouble The voltage of the signal circuit of the fuel level sensor is higher than 4.0 V.
Problem that
The fuel level gauge does not indicate normally.
appears on machine

2) Disconnect connector T01.
1 Fuel level sensor defective 3) Connect T-adapter.
Between T01 Fuel level: When FULL Resistance Max. 12 z
(female) (1) (2) Fuel level: When EMPTY Resistance 74 100 z
Disconnection in wiring har- 2) Disconnect connectors ATC3A, ATC3B, and T01.
2 (Disconnection or defective Wiring harness between ATC3B (female) (4)
Resistance Max. 1 z
contact) T01 (female) (1)
Resistance Max. 1 z
T01 (female) (2)
and standard value 2) Disconnect connectors ATC3B and T01.
in normal state 3) Insert T-adapter.
4) Turn the starting switch ON..
Voltage between
Max. 1 V
(female) (4) T01 (female) (1) T01 (female) (1)
chassis ground
4
fective
Between ATC3B Fuel level: When FULL Resistance Max. 12 z
(female) (3)
ATC3A (female) Fuel level: When EMPTY Resistance 74 100 z
(16)
20-578 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DK11KX]
[DK11KX] THROTTLE ANGLE SENSOR: OUT OF INPUT SIGNAL RANGE (KX)

Trouble Throttle angle sensor: Out of input signal range (KX)
E03 DK11KX TM
The voltage of the signal circuit of the acceleration sensor for transmission control is below 0.6 V or
Contents of trouble
above 4.7 V.
The controller controls the machine, assuming that the engine is at full throttle. (This is not related to
the engine control, however.)
Problem that Gear shift shocks become large.
appears on machine The gear is shifted up soon when the machine travels down a slope with the brake OFF.

2) Disconnect connectors ATC3A, ATC3B, and AS2.
Disconnection in wiring har- Wiring harness between ATC3B (female) (11)
1 AS2 (female) (2)
AS2 (female) (3)
Resistance Max. 1 z
AS2 (female) (1)
2) Disconnect connectors ATC3A, ATC3B, and AS2.
Resistance between
Ground fault in wiring har- Min. 1 Mz
2 (female) (6) AS2 (female) (1) AS2 (female) (1)
ness
chassis ground
Resistance between
Min. 1 Mz
(female) (11) AS2 (female) (2) AS2 (female) (2)
in normal state 2) Disconnect connectors ATC3B and AS2.
Voltage between
Max. 1 V
(female) (11) AS2 (female) (2) AS2 (female) (2)
chassis ground
Acceleration sensor defec- 4) Connect the connector.
4
tive 5) Turn the starting switch ON.
Between AS2 (1) (3) Voltage 4.6 5.4 V
Between AS2 (2) (3) Voltage 1.0 4.0 V
5
Between ATC3B (11) ATC3A (16) Voltage 1.0 4.0 V
HD465-7, HD605-7 20-579

(10)
20-580 HD465-7, HD605-7

(1)
TROUBLESHOOTING [DLE2KA]
[DLE2KA] ENGINE SPEED SENSOR: DISCONNECTION (KA)

Trouble Engine speed sensor: Disconnection (KA)
E03 DLE2KA TM
Contents of trouble The signal circuit of the engine speed sensor is disconnected and signals are not input.
The gear cannot be shifted.
Problem that
If the shift lever is set in the "N" position, the machine cannot start until it is stopped.
appears on machine
The tachometer does not operate (but indicates 0 rpm).

Press the sensor lightly against the flywheel ring gear, and then re-
Wrong adjustment of engine turn it by 1/2 3/4 turns.
1
speed sensor aFor details, see TESTING AND ADJUSTING, "Adjustment of en-
gine speed sensor".
2) Disconnect connector E03.
Engine speed sensor defec- 3) Connect T-adapter.
2
tive
Between E03 (male) (1) (2) Resistance 500 1,000 z
Possible causes Between E03 (male) (1), (2) chassis ground Resistance Min. 1 Mz
in normal state 2) Disconnect connectors ATC3A E03.
ness
E03 (female) (1)
contact)
Resistance Max. 1 z
E03 (female) (2)
Transmission controller de- 2) Disconnect connector ATC3A.
fective
Between ATC3A (female) (13) (14) Resistance 500 1,000 z
HD465-7, HD605-7 20-581

(10)
TROUBLESHOOTING [DLE2LC]
[DLE2LC] ENGINE SPEED SENSOR: *SEE SEPARATE LIST (LC)

Trouble Engine speed sensor: *See separate list (LC)
E01 DLE2LC TM
When the engine speed sensor signal is below 350 rpm, the input transmission input shaft speed sen-
Contents of trouble
sor signal is above 500 rpm.

2) Disconnect connector E03.
Engine speed sensor defec- 3) Connect T-adapter.
1
tive
Between E03 (male) (1) (2) Resistance 500 1,000 z
Between E03 (male) (1), (2) chassis ground Resistance Min. 1 Mz
2) Disconnect connectors ATC3A and E03.
ness
Possible causes Min. 1 Mz
(female) (13) E03 (female) (1) E03 (female) (1)
and standard value chassis ground
in normal state
2) Disconnect connectors ATC3A and E03.
Voltage between
Max. 1 V
(female) (13) E03 (female) (1) E03 (female) (1)
chassis ground
fective
20-582 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DLF1KA]
[DLF1KA] TRANSMISSION INPUT SHAFT SPEED SENSOR: DISCONNECTION (KA)

Trouble Transmission input shaft speed sensor: Disconnection (KA)
E03 DLF1KA TM
The signal circuit of the transmission input shaft speed sensor is disconnected and signals are not in-
Contents of trouble
put.
Problem that The lockup system is reset and the gear cannot be shifted.

Press the sensor lightly against the revolution pickup gear, and then
Wrong adjustment of trans-
return it by 1/2 1 turn.
1 mission input shaft speed
aFor details, see TESTING AND ADJUSTING, "Adjustment of trans-
sensor
mission speed sensor".
Transmission input shaft 3) Connect T-adapter.
2
speed sensor defective
Between CN3 (male) (1) (2) Resistance 500 1,000 z
Possible causes Between CN3 (male) (1), (2) chassis ground Resistance Min. 1 Mz
in normal state 2) Disconnect connectors ATC3A and CN3.
ness
CN3 (female) (1)
contact)
Resistance Max. 1 z
CN3 (female) (2)
fective
HD465-7, HD605-7 20-583

(10)
TROUBLESHOOTING [DLF1LC]
[DLF1LC] TRANSMISSION INPUT SHAFT SPEED SENSOR: *SEE SEPARATE LIST (LC)

Trouble Transmission input shaft speed sensor: *See separate list (LC)
E03 DLF1LC TM
The speed calculated from the engine speed sensor signal, transmission intermediate shaft speed sen-
Contents of trouble sor signal, and transmission output shaft speed sensor signal is different from the signal speed of the
transmission input shaft speed sensor.

Transmission input shaft 3) Connect T-adapter.
1
ness
in normal state
Voltage between
Max. 1 V
chassis ground
fective
20-584 HD465-7, HD605-7

(10)
[DLF2KA] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: DISCONNECTION

(KA)
Action code Failure code Controller code Transmission intermediate shaft speed sensor: Disconnection
Trouble
E03 DLF2KA TM (KA)
The signal circuit of the transmission intermediate shaft speed sensor is disconnected and signals are
Contents of trouble
not input.

1 mission intermediate shaft
speed sensor
Transmission intermediate 2) Disconnect connector CN4.
2 shaft speed sensor defective 3) Connect T-adapter.
in normal state 2) Disconnect connectors ATC3A CN4.
ness
CN4 (female) (1)
contact)
Resistance Max. 1 z
CN4 (female) (2)
fective
HD465-7, HD605-7 20-585

(10)
[DLF2LC] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR:

*SEE SEPARATE LIST (LC)
Action code Failure code Controller code Transmission intermediate shaft speed sensor: *See separate list
Trouble
E03 DLF2LC TM (LC)
The speed calculated from the engine speed sensor signal, transmission input shaft speed sensor sig-
Contents of trouble nal, and transmission output shaft speed sensor signal is different from the signal speed of the trans-
mission intermediate shaft speed sensor.

Transmission intermediate 3) Connect T-adapter.
1
shaft speed sensor defective
2) Disconnect connectors ATC3A CN4.
ness
in normal state
Voltage between
Max. 1 V
chassis ground
fective
20-586 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DLT3KA]
[DLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTION (KA)

Trouble Transmission output shaft speed sensor: Disconnection (KA)
E03 DLT3KA TM
The signal circuit of the transmission output shaft speed sensor is disconnected and signals are not
Contents of trouble
input.
appears on machine If the shift lever is set in the "N" position, the gear is set in neutral

return it by 1/2 - 1 turn.
1 mission output shaft speed
sensor
Transmission output shaft 3) Connect T-adapter.
2
in normal state 2) Disconnect connectors ATC3A CN5.
ness
CN5 (female) (1)
contact)
Resistance Max. 1 z
CN5 (female) (2)
fective
HD465-7, HD605-7 20-587

(10)
TROUBLESHOOTING [DLT3LC]
[DLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: *SEE SEPARATE LIST

(LC)

Trouble Transmission output shaft speed sensor: *See separate list (LC)
E03 DLT3LC TM
The speed calculated from the engine speed sensor signal, transmission input shaft speed sensor sig-
Contents of trouble nal, and transmission intermediate shaft speed sensor signal is different from the signal speed of the
transmission output shaft speed sensor.
appears on machine If the shift lever is set in the "N" position, the gear is set in neutral.

1
2) Disconnect connectors ATC3A, BRC3A, and CN5.
2 ATC3A (female) (3),
ness Wiring harness between ATC3A
BRC3A (female) (13),
(female) (3) BRC3A (female) (13) Min. 1 Mz
Possible causes CN5 (female) (1)
CN5 (female) (1)
2) Disconnect connectors ATC3A, BRC3A, CN5.
3 Hot short in wiring harness Voltage between
(female) (3) BRC3A (female) (13) BRC3A (female) (13), Max. 1 V
CN5 (female) (female) (1) CN5 (female) (1)
chassis ground
fective
20-588 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DLT3KA]
HD465-7, HD605-7 20-589

(1)
TROUBLESHOOTING [DXH1KA]
[DXH1KA] DISCONNECTION IN OUTPUT CIRCUIT OF LOCKUP CLUTCH SOLENOID:

DISCONNECTION (KA)
Action code Failure code Controller code Disconnection in output circuit of lockup clutch solenoid: Discon-
Trouble
E03 DXH1KA TM nection (KA)
Contents of trouble When a signal is output to the lockup clutch ECMV, any current does not flow.
Action of controller The controller turns the lockup operation OFF.
Problem that
The lockup system does not operate.
appears on machine
Related information This failure can be checked in the monitoring function (Code: 31519, 31609, 31619)

1
tive Between CN20 (male) (1) (2) Resistance 5 15 z
Between CN20 (male) (1), (2) chassis
ground
Possible causes 2) Disconnect connectors ATC2 and CN20.
CN20 (female) (1)
contact)
Resistance Max. 1 z
CN20 (female) (2)
3
fective
Resistance 5 15 z
ATC2 (female) (20)
20-590 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DXH1KB]
[DXH1KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF LOCKUP CLUTCH SOLENOID:

SHORT CIRCUIT (KB)
Action code Failure code Controller code Short circuit in output circuit of lockup clutch solenoid: Short cir-
Trouble
E03 DXH1KB TM cuit (KB)
When a signal is output to the lockup clutch ECMV, an abnormally large current flows, or some current
Contents of trouble
is flowing while the signal is OFF.
The lockup system is reset and the gear cannot be shifted.
Problem that
If the shift lever is set in the "N" position, the machine cannot start until it is stopped. (The machine
appears on machine
cannot start again, depending on the failure condition.)

1
tive
2) Disconnect connectors ATC2 and CN10.
Possible causes Resistance between
and standard value Short circuit in wiring har- Wiring harness between ATC2 (fe- ATC2 (female) (10),
in normal state 2 Min. 1 Mz
ness male) (10) CN20 (female) (1) CN20 (female) (1)
chassis ground
CN20 (female) (1) and between ATC2 (female) Resistance Min. 1 Mz
(20) CN20 (female) (2)
3
fective
Resistance 5 15 z
ATC2 (female) (20)
HD465-7, HD605-7 20-591

(10)
[DXH2KA] DISCONNECTION IN OUTPUT CIRCUIT OF HI CLUTCH SOLENOID:

DISCONNECTION (KA)
Action code Failure code Controller code Disconnection in output circuit of Hi clutch solenoid: Disconnec-
Trouble
E03 DXH2KA TM tion (KA)
Contents of trouble When a signal is output to the Hi clutch ECMV, any current does not flow.
Problem that The gear is set in neutral during travel.
appears on machine The machine cannot start again until it is stopped.

1 Hi clutch ECMV defective
Between CN18 (male) (1), (2) chassis
ground
Possible causes 2) Disconnect connectors ATC2 and CN18.
CN18 (female) (1)
contact)
Resistance Max. 1 z
CN18 (female) (2)
3
fective
Resistance 5 15 z
ATC2 (female) (19)
20-592 HD465-7, HD605-7

(10)
[DXH2KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF HI CLUTCH SOLENOID:

SHORT CIRCUIT (KB)
Action code Failure code Controller code Short circuit in output circuit of Hi clutch solenoid: Short circuit
Trouble
E03 DXH2KB TM (KB)
When a signal is output to the Hi clutch ECMV, an abnormally large current flows, or some current is
Contents of trouble
flowing while the signal is OFF.
The gear is set in Neutral during travel.
Problem that
The machine cannot start until it is stopped. (The machine cannot start again, depending on the failure
appears on machine
condition.)

chassis ground
(19) CN18 (female) (2)
3
fective
Resistance 5 15 z
ATC2 (female) (19)
HD465-7, HD605-7 20-593

(10)
20-594 HD465-7, HD605-7

(7)
[DXH3KA] DISCONNECTION IN OUTPUT CIRCUIT OF LO CLUTCH SOLENOID:

DISCONNECTION (KA)
Action code Failure code Controller code Disconnection in output circuit of Lo clutch solenoid: Disconnec-
Trouble
Contents of trouble When a signal is output to the Lo clutch ECMV, any current does not flow.
Problem that The gear is set in Neutral during travel.

in normal state 2 Wiring harness between ATC2 (female) (7)
CN16 (female) (1)
contact)
Resistance Max. 1 z
CN16 (female) (2)
3
fective
Resistance 5 15 z
ATC2 (female) (17)
HD465-7, HD605-7 20-595

(10)
[DXH3KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF LO CLUTCH SOLENOID: SHORT

CIRCUIT (KB)
Action code Failure code Controller code Short circuit in output circuit of Lo clutch solenoid: Short circuit
Trouble
E03 DXH3KB TM (KB)
When a signal is output to the Lo clutch ECMV, an abnormally large current flows, or some current is
Contents of trouble
Problem that
The machine cannot start until it is stopped.
appears on machine
(The machine cannot start again, depending on the failure condition.)

chassis ground
(17) CN16 (female) (2)
3
fective
Resistance 5 15 z
ATC2 (female) (17)
20-596 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-597

(7)
[DXH4KA] DISCONNECTION IN OUTPUT CIRCUIT OF 1ST CLUTCH SOLENOID:

DISCONNECTION (KA)
Action code Failure code Controller code Disconnection in output circuit of 1st clutch solenoid: Disconnec-
Trouble
Contents of trouble When a signal is output to the 1st clutch ECMV, any current does not flow.

CN6 (female) (1)
contact)
Resistance Max. 1 z
CN6 (female) (2)
3
fective
Resistance 5 15 z
ATC2 (female) (13)
20-598 HD465-7, HD605-7

(10)
[DXH4KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 1ST CLUTCH SOLENOID: SHORT

CIRCUIT (KB)
Action code Failure code Controller code Short circuit in output circuit of 1st clutch solenoid: Short circuit
Trouble
E03 DXH4KB TM (KB)
When a signal is output to the 1st clutch ECMV, an abnormally large current flows, or some current is
Contents of trouble
Problem that
appears on machine

chassis ground
(13) CN6 (female) (2)
3
fective
Resistance 5 15 z
ATC2 (female) (13)
HD465-7, HD605-7 20-599

(10)
[DXH5KA] DISCONNECTION IN OUTPUT CIRCUIT OF 2ND CLUTCH SOLENOID:

DISCONNECTION (KA)
Action code Failure code Controller code Disconnection in output circuit of 2nd clutch solenoid: Disconnec-
Trouble
Contents of trouble When a signal is output to the 2nd clutch ECMV, any current does not flow.

2) Disconnect connectors ATC2 CN8.
CN8 (female) (1)
contact)
Resistance Max. 1 z
CN8 (female) (2)
3
fective
Resistance 5 15 z
ATC2 (female) (15)
20-600 HD465-7, HD605-7

(10)
[DXH5KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 2ND CLUTCH SOLENOID: SHORT

CIRCUIT (KB)
Action code Failure code Controller code Short circuit in output circuit of 2nd clutch solenoid: Short circuit
Trouble
E03 DXH5KB TM (KB)
When a signal is output to the 2nd clutch ECMV, an abnormally large current flows, or some current is
Contents of trouble
Problem that
appears on machine

chassis ground
(15) CN8 (female) (2)
3
fective
Resistance 5 15 z
ATC2 (female) (15)
HD465-7, HD605-7 20-601

(10)
[DXH6KA] DISCONNECTION IN OUTPUT CIRCUIT OF 3RD CLUTCH SOLENOID:

DISCONNECTION (KA)
Action code Failure code Controller code Disconnection in output circuit of 3rd clutch solenoid: Disconnec-
Trouble
Contents of trouble When a signal is output to the 3rd clutch ECMV, any current does not flow.

2) Disconnect connectors ATC2 CN12.
CN12 (female) (1)
contact)
Resistance Max. 1 z
CN12 (female) (2)
3
fective
Resistance 5 15 z
ATC2 (female) (18)
20-602 HD465-7, HD605-7

(10)
[DXH6KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 3RD CLUTCH SOLENOID: SHORT

CIRCUIT (KB)
Action code Failure code Controller code Short circuit in output circuit of 3rd clutch solenoid: Short circuit
Trouble
E03 DXH6KB TM (KB)
When a signal is output to the 3rd clutch ECMV, an abnormally large current flows, or some current is
Contents of trouble
Problem that
The machine cannot start until it is stopped. (The machine cannot start again, depending on the failure
appears on machine
condition.)

chassis ground
(18) CN12 (female) (2)
3
fective
Resistance 5 15 z
ATC2 (female) (18)
HD465-7, HD605-7 20-603

(10)
[DXH7KA] DISCONNECTION IN OUTPUT CIRCUIT OF R CLUTCH SOLENOID:

DISCONNECTION (KA)
Action code Failure code Controller code Disconnection in output circuit of R clutch solenoid: Disconnec-
Trouble
Contents of trouble When a signal is output to the R clutch ECMV, any current does not flow.

CN10 (female) (1)
contact)
Resistance Max. 1 z
CN10 (female) (2)
3
fective
Resistance 5 15 z
ATC2 (female) (15)
20-604 HD465-7, HD605-7

(10)
[DXH7KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF R CLUTCH SOLENOID: SHORT

CIRCUIT (KB)
Action code Failure code Controller code Short circuit in output circuit of R clutch solenoid: Short circuit
Trouble
E03 DXH7KB TM (KB)
When a signal is output to the R clutch ECMV, an abnormally large current flows, or some current is
Contents of trouble
Problem that
appears on machine

chassis ground
(15) CN10 (female) (2)
3
fective
Resistance 5 15 z
ATC2 (female) (15)
HD465-7, HD605-7 20-605

(10)
TROUBLESHOOTING [DXHHKA]
[DXHHKA] DISCONNECTION IN OUTPUT CIRCUIT OF 4TH CLUTCH SOLENOID:

DISCONNECTION (KA)
Action code Failure code Controller code Disconnection in output circuit of 4th clutch solenoid: Disconnec-
Trouble
E03 DXHHKA TM tion (KA)
Contents of trouble When a signal is output to the 4th clutch ECMV, any current does not flow.

CN14 (female) (1)
contact)
Resistance Max. 1 z
CN14 (female) (2)
3
fective
Resistance 5 15 z
ATC2 (female) (13)
20-606 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DXHHKB]
[DXHHKB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 4TH CLUTCH SOLENOID: SHORT

CIRCUIT (KB)
Action code Failure code Controller code Short circuit in output circuit of 4th clutch solenoid: Short circuit
Trouble
E03 DXHHKB TM (KB)
When a signal is output to the 4th clutch ECMV, an abnormally large current flows, or some current is
Contents of trouble
Problem that
appears on machine

chassis ground
(13) CN14 (female) (2)
3
fective
Resistance 5 15 z
ATC2 (female) (13).
HD465-7, HD605-7 20-607

(10)
TROUBLESHOOTING TM-1
TM-1 FUEL LEVEL GAUGE DOES NOT OPERATE NORMALLY

(IT ALWAYS INDICATES "FULL")
Action code Failure code Controller code Fuel level gauge does not operate normally
Trouble
Not set Not set Not set (It always indicates "FULL")
The fuel level gauge does not operate normally because of grounding fault (short circuit with GND) in
Contents of trouble
the signal circuit of the fuel level sensor.
Problem that
The fuel level gauge always indicates "FULL".
appears on machine
Related information If failure code "DJF1KA" is indicated, perform troubleshooting for it first.

1 Fuel level sensor defective 3) Connect T-adapter.
Between T01 Fuel level: When FULL Resistance Max. 12 z
Possible causes (female) (1) (2) Fuel level: When EMPTY Resistance 74 100 z
and standard value
in normal state
2) Disconnect connectors ATC3B and T01.
ness
Min. 1 Mz
chassis ground
20-608 HD465-7, HD605-7

(10)
TM-2 ABNORMALITY IN BACKUP LAMP AND BACKUP BUZZER

a) When the shift lever is set in the "R" position, the backup lamp and backup buzzer are not turned ON
Action code Failure code Controller code Abnormality in backup lamp and backup buzzer
Trouble a) When the shift lever is set in the "R" position, the backup lamp
Not set Not set Not set and backup buzzer are not turned ON
Contents of trouble When the shift lever is set in the "R" position, the backup lamp and backup buzzer are not turned ON
Problem that
When the shift lever is set in the "R" position, the backup lamp and backup buzzer are not turned ON
appears on machine
Before starting troubleshooting, check that fuse (BT-1) (16) is normal.
Related information
Failure code is not displayed.

Relay (R05)
No
When the backup lamp and buzzer relay (R05) is normal.
is replaced, is failure repaired? Relay (R05)
Yes
is defective.
Backup lamp and buzzer re- 3) Check the relay.
1
lay (R05) defective
3) Check the relay.
Apply 24 V between
Resistance Max. 1 z
tween (5) (6).
Diode (D05)
No
Possible causes When diode (D05) is replaced, is failure re- is normal.
and standard value 2 Diode (D05) defective paired? Diode (D05)
in normal state Yes
is defective.
2) Disconnect connectors ATC5B, CNS2, R05, CJT, diode (D05), and
fuse (16) terminal.
Wiring harness between fuse BT1 terminal
Resistance Max. 1 z
(16) R05 (female) (4)
Disconnection in wiring har- Wiring harness between R05 (female) (5)
3 D05 (female) (1)
contact) Wiring harness between D05 (female) (2)
ATC5B (female) (2), and branch point of CNS Resistance Max. 1 z
(female) (3)
Resistance Max. 1 z
chassis ground
Resistance Max. 1 z
CJT (female) (8)
Joint con-
No nector (CJT)
Joint connector (CJT) defec- When joint connector (CJT) is replaced, if fail- is normal
4
tive ure repaired? Joint con-
Yes nector (CJT)
is defective
HD465-7, HD605-7 20-609

(10)
b) Backup lamp is not turned ON (Backup buzzer is normal)
Trouble
Not set Not set Not set b) Abnormality in backup lamp and backup buzzer
When the shift lever is set in the "R" position, the backup lamp is not turned ON (The backup buzzer is
Contents of trouble
normal).
Problem that When the shift lever is set in the "R" position, the backup lamp is not turned ON (The backup buzzer is
appears on machine normal).
Related information Failure code is not displayed.

Backup lamp bulb is not broken. Backup lamp is normal
1 Backup lamp defective
Backup lamp bulb is broken. Backup lamp is defective
Disconnection in wiring har- 2) Disconnect connectors B04 and CJT.
Possible causes 2
and standard value Wiring harness between CJT (female) (2)
in normal state
B04 terminal
Joint con-
No nector (CJT)
Joint connector (CJT) defec- When joint connector (CJT) is replaced, is fail- is normal
3
Yes nector (CJT)
is defective
c) Backup buzzer is not turned ON (Backup lamp is normal)
Trouble
Not set Not set Not set c) Backup buzzer is not turned ON (Backup lamp is normal)
When the shift lever is set in the "R" position, the backup buzzer is not turned ON (The backup lamp is
Contents of trouble
normal).
Problem that When the shift lever is set in the "R" position, the backup buzzer is not turned ON (The backup lamp is
appears on machine normal).
Cause Standard value in normal state/Remarks ON troubleshooting

2) Disconnect connectors B05, B06, and CJT.
Disconnection in wiring har- Wiring harness between CJT (female) (6)
1 chassis ground
Wiring harness between B06 terminal CJT
(female) (7) terminal
Possible causes
Wiring harness between B05 terminal CJT
in normal state (female) (1) terminal
When results of Item a) and Cause 1 above are Backup buzzer is
2 Backup buzzer defective
normal defective
Joint con-
No nector (CJT)
Joint connector (CJT) defec- When joint connector (CJT) is replaced, is fail- is normal
3
Yes nector (CJT)
is defective
20-610 HD465-7, HD605-7

(10)
d) While shift lever is not operated, backup lamp and backup buzzer are turned ON
Trouble d) While shift lever is not operated, backup lamp and backup
Not set Not set Not set buzzer are turned ON
Contents of trouble While shift lever is not operated, backup lamp and backup buzzer are turned ON.
Problem that
While shift lever is not operated, backup lamp and backup buzzer are turned ON.
appears on machine

Relay (R05)
No
When the backup lamp and buzzer relay (R05) is normal.
is replaced, is failure repaired? Relay (R05)
Yes
is defective.
Backup lamp and buzzer re- 3) Check the relay.
1
lay (R05) defective
3) Check the relay.
Apply 24 V between
Resistance Max. 1 z
Possible causes tween (5) (6).
in normal state 2) Disconnect connectors ATC5B, CNS2, R05, CJT, diode (D05), and
fuse (16) terminal.
Voltage between R05
Wiring harness between R05 (fe- (female) (5), D05 (fe-
Max. 1 V
male) (5) D05 (female) (1) male) (1) chassis
ground
Wiring harness between D05 (fe-
Voltage between D05
male) (2) ATC5B (female) (2), Max. 1 V
and branch point of CNS (female)
2 Hot short in wiring harness ground
(3)
Voltage between R05
Wiring harness between R05 (fe- (female) (3), CJT (fe- Max. 1 V
male) (3) CJT (female) (8) male) (8) chassis
ground
Voltage between CJT
Wiring harness between CJT (fe- Max. 1 V
(female) (1), B05 termi-
male) (1) B05 terminal
nal chassis ground
Voltage between CJT
Wiring harness between CJT (fe-
(female) (2), B04 termi- Max. 1 V
male) (2) B04 terminal
nal chassis ground
HD465-7, HD605-7 20-611

(10)
20-612 HD465-7, HD605-7

(1)
TROUBLESHOOTING FOR RETARDER
CONTROLLER SYSTEM
(BK MODE)
Electrical system diagram related to retarder control .................................................................................. 20-704

Information in troubleshooting table ....................................................................................................... 20-706
Phenomenon code table ........................................................................................................................ 20-707
[2G42ZG] Accumulator (front): lowering of oil pressure (ZG).............................................................. 20-708
[2G43ZG] Accumulator (rear): lowering of oil pressure (ZG) .............................................................. 20-708
[D1C0KZ] Brake cutout relay: disconnection or short circuit (KZ) ....................................................... 20-709
[D5ZNKZ] Failure of front brake cutout output system (disconnection, grounding fault, short circuit)
(if equipped): disconnection or short circuit (KZ) ................................................................ 20-711
[DB10KK] Retarder controller: lowering of source/input voltage (KK) ................................................. 20-713
[DB11KK] Main power line of retarder controller: lowering of source/input voltage (KK) .................... 20-715
[DB12KK] Retarder controller load power line: lowering of source/input voltage (KK) ........................ 20-717
[DB13KK] Direct power source line of retarder controller battery:
lowering of source/input voltage (KK)................................................................................. 20-719
[DB19KM] Retarder controller wiring harness: mistake in operation or setting (KM) ........................... 20-720
[DB1SKQ] Wrong information on model selection: disagreement of model selection signals (KQ)..... 20-721
[DDD7KX] Failure in travel speed set switch system (if equipped): out of input signal range (KX) ..... 20-722
[DDD8KA] ARSC system switch system: disconnection (KA).............................................................. 20-724
[DDD8KB] ARSC system switch system: short circuit (KB) ................................................................. 20-725
[dGR2L8] Failure In retarder oil temperature sensor system: *see separate list (L8) ......................... 20-726
[DGR2L8] Brake oil temperature sensor (rear): *see separate list (L8)............................................... 20-727
[dHP4KX] Failure in suspension pressure sensor (FR) system (if equipped):
out of input signal range (KX) .............................................................................................. 20-728
[DHP4KX] Failure in suspension pressure sensor (FR) system (if equipped):
[dHP5KX] Failure in suspension pressure sensor (FL) system (if equipped):
[DHP5KX] Failure in suspension pressure sensor (FL) system (if equipped):
[DHU2KX] Accumulator oil pressure sensor (front): out of input signal range (KX) ............................. 20-736
[DHU3KX] Accumulator oil pressure sensor (rear): out of input signal range (KX).............................. 20-738
[dK11KX] Failure in acceleration sensor system (if equipped): out of input signal range (KX)........... 20-740
[DK11KX] Failure in acceleration sensor system (if equipped): out of input signal range (KX)........... 20-741
[DK51L5] Retarder lever potentiometer: *see separate list (L5) ......................................................... 20-742
[DK52KX] Dump lever potentiometer 1: out of input signal range (KX)............................................... 20-745
[DK53L8] Dump lever potentiometer 2: *see separate list (L8) .......................................................... 20-747
[DK54KX] Body positioner sensor: out of input signal range (KX) ...................................................... 20-748
[DKD0L6] Failure in steering speed sensor (if equipped): *see separate list (L6) .............................. 20-750
[dLt3KA] Transmission output shaft speed sensor: disconnection (KA)............................................ 20-752
[dLT3KA] Transmission output shaft speed sensor: disconnection (KA)............................................ 20-753
[DW35KZ] Failure in output system of auto suspension solenoid 1 (if equipped) (disconnection,
grounding fault, short circuit): disconnection or short circuit (KZ)....................................... 20-754
[DW36KZ] Failure in output system of auto suspension solenoid 2 (if equipped) (disconnection,
grounding fault, short circuit): disconnection or short circuit (KZ)....................................... 20-755
[DW72KZ] Failure in kick-out solenoid output system (D_OUT3) (disconnection, grounding fault,
short circuit): disconnection or short circuit (KZ) ................................................................ 20-756
[DW73KZ] Failure in hoist select valve output system (D_OUT5) (disconnection, grounding fault,
short circuit): disconnection or short circuit (KZ) ................................................................ 20-758
[DK11K4] Proportional solenoid pressure reducing valve of rear wheel: Uncontrollable (K4) ......... 20-759-1
[DX11KA] Disconnection in output circuit of proportional solenoid pressure reducing valve
of rear wheel (A_OUT2): disconnection (KA) ..................................................................... 20-760
HD465-7, HD605-7 20-701

(10)
[DX11KB] Short circuit in output circuit of proportional solenoid pressure reducing valve
of rear wheel (A_OUT2): short circuit (KB)......................................................................... 20-761
[DX11KY] Grounding fault in output circuit of proportional solenoid pressure reducing valve
of rear wheel (A_OUT2): short circuit with power source line (KY) .................................... 20-762
[DX11MA] Proportional solenoid pressure reducing valve of rear wheel: Malfunction (MA)............. 20-762-1
[DX13KA] Disconnection in output circuit of hoist EPC valve (A_OUT3): disconnection (KA)............ 20-763
[DX13KB] Grounding fault in output circuit of hoist EPC valve (A_OUT3): short circuit (KB) ............. 20-764
[DX13KY] Short circuit in output circuit of hoist EPC valve (A_OUT3): short circuit with
power source line (KY) ......................................................................................................... 20-765
BK-1 Parking brake does not operate normally........................................................................... 20-767
a) When the parking brake switch is set in the OFF position, the parking brake
is not released............................................................................................................... 20-767
b) When the parking brake switch is set in the PARK position, the parking brake
does not work................................................................................................................ 20-769
BK-2 Retarder brake oil temperature gauge does not operate normally ..................................... 20-771
BK-3 Inclination alarm is turned ON when dump body is raised (when machine is not inclined
more than 15).................................................................................................................... 20-772
BK-4 Touch up/down and cancellation cannot be performed ...................................................... 20-773
20-702 HD465-7, HD605-7

(10)
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED TO RETARDER CONTROL
ELECTRICAL SYSTEM DIAGRAM RELATED TO RETARDER

CONTROL
20-704 HD465-7, HD605-7

(2)
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED TO RETARDER CONTROL
HD465-7, HD605-7 20-705

(5)

panel panel panel
Problem that
appears on machine

Remarks on judgment
1
Disconnection
Ground fault
Short circuit
indicate priority)
side.
side.
5
side.
20-706 HD465-7, HD605-7

(10)


Regarding phenomenon code provided with instruction "Refer to table", check it against table below.
Phenomenon Contents Phenomenon Contents
code code
KA Disconnection in wiring L0 Fill signals at two or more channels which are not set as combi-
nation are turned ON at the same time.
KK Source voltage reduction/ L2 Fuel pressure is above maxim specified value.

input
KQ Type select signal incon- L3 Object part is uncontrollable.

sistency
KY Short circuit with power LC rpm signals in two systems are inconsistent.
source (Hot short)
KZ Disconnection or short cir- LD Switch is pressed for usually unthinkable long time.
cuit
MW Sliding
NS Overheat
HD465-7, HD605-7 20-707

(10)
TROUBLESHOOTING [2G42ZG], [2G43ZG]
[2G42ZG] ACCUMULATOR (FRONT): LOWERING OF OIL PRESSURE (ZG)

Trouble Accumulator (Front): Lowering of oil pressure (ZG)
E03 2G42ZG BK
The signal of the front accumulator oil pressure sensor lowers below 13.2 MPa {135 kg/cm2} while the
Contents of trouble
engine is running (continuously for more than 30 seconds).
Problem that
If the machine is used without repairing, the front brake may not work.
appears on machine
Related information This failure can be checked in the monitoring function (Code: 35500)

The front accumulator (brake) oil pressure is normal.
Possible causes Lowering of front accumula-
1 aIf the oil pressure is not normal, perform troubleshooting for hy-
and standard value tor (brake) oil pressure
draulic/mechanical system.
in normal state
If the front accumulator (brake) oil pressure is normal, the retarder
2 Retarder controller defective
controller is defective.
[2G43ZG] ACCUMULATOR (REAR): LOWERING OF OIL PRESSURE (ZG)

Trouble Accumulator (Rear): Lowering of oil pressure (ZG)
E03 2G43ZG BK
The signal of the rear accumulator oil pressure sensor lowers below 8.83 MPa {90 kg/cm2} while the
Contents of trouble
engine is running (continuously for more than 30 seconds).
Problem that
If the machine is used without repairing, the rear brake may not work.
appears on machine

The rear accumulator (brake) oil pressure is normal.
Possible causes Lowering of rear accumula-
1 aIf the oil pressure is not normal, perform troubleshooting for hy-
and standard value tor (brake) oil pressure
draulic/mechanical system.
in normal state
If the rear accumulator (brake) oil pressure is normal, the retarder
controller is defective.
20-708 HD465-7, HD605-7

(10)
TROUBLESHOOTING [D1C0KZ]
[D1C0KZ] BRAKE CUTOUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ)

Action code Failure code Controller code Brake cutout relay: Disconnection or short circuit (KZ)
Trouble
E03 D1C0KZ BK (Disconnection, grounding fault, or short circuit)
When the output to the brake cutout relay circuit is turned ON, an abnormally large current flows or any
Contents of trouble
current does not flow. Or, some current is flowing while the output is OFF.
The controller turns the output to the brake cutout relay OFF.
When ARSC operates, the controller releases the brake gradually.
The retarder controller system does not operate at all. (Retarder, dump, auto suspension, ARSC,
Problem that
ASR)
appears on machine
Failure codes (DB12KK, DHU2KX, DHU3KX) are displayed, too.

When the brake cutout relay (R14) No Relay (R14) is normal
is replaced, is failure repaired? Yes Relay (R14) is defective
3) Check the relay.
Brake cutout relay (R14) de-
1 Between R14 (male) (1) (2) Resistance 200 400 z
fective
3) Check the relay.
Apply 24 V between
Resistance Max. 1 z
Between R14 (male) (1) (2)
Resistance Min. 1 M z
tween (1) (2)
2) Disconnect connectors BRC1 and R14.
Possible causes Wiring harness between fuse BR- Voltage between BRC1
20 30 V
and standard value 3-(12) BRC1 (female) (4) (4) chassis ground
in normal state
Disconnection in wiring har- Wiring harness between fuse BT- Voltage between R14 20 30 V
ness 3-(12) R14 (female) (5) (5) chassis ground
2
(Disconnection or defective 1) Turn the starting switch OFF.
contact) 2) Disconnect connectors BRC1, BRC2, and R14.
Wiring harness between BRC2 (female) (1),
Resistance Max. 1 z
(12) R14 (female) (3)
Resistance Max. 1 z
chassis ground
Wiring harness between BRC1 (female) (13)
Resistance Max. 1 z
R14 (female) (1)
3
ness Wiring harness between Resistance between BRC1
BRC1 (female) (13) R14 (female) (13), R14 (female) Min. 1 M z
4 Hot short in wiring harness 4) Turn the starting switch ON.
Wiring harness between Voltage between BRC1 (fe-
BRC1 (female) (13) R14 male) (13), R14 (female) (1) Max. 1 V
HD465-7, HD605-7 20-709

(10)
TROUBLESHOOTING [D1C0KZ]
20-710 HD465-7, HD605-7

(1)
TROUBLESHOOTING [D5ZNKZ]
[D5ZNKZ] FAILURE OF FRONT BRAKE CUTOUT OUTPUT SYSTEM

(DISCONNECTION, GROUNDING FAULT, SHORT CIRCUIT) (IF EQUIPPED):
DISCONNECTION OR SHORT CIRCUIT (KZ)
Action code Failure code Controller code Failure of front brake cutout output system (Disconnection, grounding
Trouble fault, short circuit) (if equipped): Disconnection or short circuit (KZ)
E03 D5ZNKZ BK (Disconnection, grounding fault, or short circuit)
When the output to the front brake cutout switch circuit is turned ON, an abnormally large current flows
Contents of trouble
or any current does not flow. Or, some current is flowing while the output is OFF.
Action of controller The controller turns the output to the brake cutout switch circuit OFF.
Problem that When the front brake cutout switch is turned ON, the front brake cutout system does not work. Or, the
appears on machine front brake cutout system works while the switch is OFF.
Related information This failure can be checked in the monitoring function (Code: 37600, 39100)

2) Disconnect connector FBC.
3) Check the switch.
Turn the front brake cutout
Front brake cutout switch Resistance Min. 1 M z
1 Between FBC switch OFF (Press it up).
defective
(male) (1) (3) Turn the front brake cutout
Resistance Max. 1 z
switch ON (Press it down).
aWhen the front brake cutout switch is turned ON (pressed down), the
front brake is cut out (the front brake does not operate).
2) Disconnect connectors DPC2B and FBC.
Disconnection in wiring har- Wiring harness between DPC2B (female) (4)
2 FBC (female) (3)
Wiring harness between fuse BTC-4 (8) FBC
(female) (1)
Wiring harness between FBC (female) (1)
Resistance Max. 1 z
chassis ground
and standard value
in normal state Resistance between
Ground fault in wiring har- Wiring harness between DPC2B DPC2B (female) (4),
3 Min. 1 M z
ness (female) (4) FBC (female) (3) FBC (female) (3)
chassis ground
Wiring harness between fuse Resistance between
BTC-4 (8) FBC (female) (1) FBC (female) (1) Min. 1 M z
In this case, the fuse is broken. chassis ground
Wiring harness between Voltage between DPC2B (fe-
DPC2B (female) (4) FBC male) (4), FBC (female) (3) Max. 1 V
2) Disconnect connector DPC2B
Turn the cutout switch OFF
Between Voltage 20 30 V
(Press it up).
DPC2B (4)
chassis ground Turn the cutout switch ON
Voltage Max. 1 V
(Press it down).
HD465-7, HD605-7 20-711

(10)
TROUBLESHOOTING [D5ZNKZ]
20-712 HD465-7, HD605-7

(1)
TROUBLESHOOTING [DB10KK]
[DB10KK] RETARDER CONTROLLER: LOWERING OF SOURCE/INPUT VOLTAGE (KK)

Trouble Retarder controller: Lowering of source/input voltage (KK)
E03 DB10KK BK
The voltages of both main power source voltage circuit and direct power source voltage circuit are be-
Contents of trouble
low 17 V.
Action of controller None in particular. (The controller works as long as possible.)
Problem that
appears on machine
If failure code "ABOOMA" (Malfunction of alternator) is indicated, perform troubleshooting for it first.
Related information If the fuse is broken, check the line between the fuse and BRC1 (female) (7), (9), (17) for grounding
fault.

1) Test the battery voltage and specific gravity of the battery fluid.
1 Battery defective Battery voltage Voltage Min. 24 V
Specific gravity of battery fluid Specific gravity Min. 1.26
2) Disconnect connector BRC1.
Resistance Max. 1 z
(16) chassis ground
ness Voltage between
2
(Disconnection or defective Wiring harness between battery, battery BRC1 (7) (8), 20 30 V
contact) relay terminal B, BRC1 (7)
(16)
Possible causes
and standard value
in normal state
Voltage between
Wiring harness between battery relay
BRC1 (9), (17) 20 30 V
terminal M BRC1 (9), (17)
(8), (16)
2) Disconnect connector BRC1
Between BRC1 (7) (8), (16) Voltage 20 30 V
3 Retarder controller defective 1) Turn the starting switch OFF.
Between BRC1 (9), (17) (8), (16) Voltage 20 30 V
HD465-7, HD605-7 20-713

(10)
20-714 HD465-7, HD605-7

(1)
[DB11KK] MAIN POWER LINE OF RETARDER CONTROLLER: LOWERING OF

Action code Failure code Controller code Main power line of retarder controller: Lowering of source/input volt-
Trouble
E03 DB11KK BK age (KK)
Contents of trouble The difference between the main power source voltage and direct power source voltage is 5 V or more.
Problem that
appears on machine
Related information If the fuse is broken, check the line between the fuse and BRC1 (female) (9) (17) for grounding fault.

Resistance Max. 1 z
(16) chassis ground
ness Voltage between bat-
1
(Disconnection or defective Wiring harness between battery tery relay terminal B 20 30 V
contact) battery relay terminal B
in normal state 2) Disconnect connector BRC1.
Voltage between
Wiring harness between battery
BRC1 (9), (17) (8), 20 30 V
relay terminal M BRC1 (9), (17)
(16)
Between BRC1 (9), (17) (8), (16) Voltage 20 30 V
HD465-7, HD605-7 20-715

(10)
20-716 HD465-7, HD605-7

(1)
[DB12KK] RETARDER CONTROLLER LOAD POWER LINE: LOWERING OF SOURCE/

INPUT VOLTAGE (KK)
Action code Failure code Controller code Retarder controller load power line: Lowering of source/input
Trouble
E03 DB12KK BK voltage (KK)
Contents of trouble While the controller source voltage is normal, the solenoid source voltage is below 17 V.
The controller turns the all output circuits OFF..
The controller turns the 24 V sensor power source OFF.
Problem that
ASR)
appears on machine
Failure codes (DHU2KX, DHU3KX) are displayed, too.
Related information If the fuse is broken, check the line between the fuse BRC1 (female) (4) (17) for grounding fault.

When brake cutout relay (R14) is No Relay (R14) is normal.
replaced, is failure repaired? Yes Relay (R14) is defective.
3) Check the relay.
Brake cutout relay (R14) de-
1
fective Between R14 (male) (1) (2) Resistance 200 400 z
3) Check the relay.
Apply 24 V between
Resistance Max. 1 z
Between R14 (male) (1) (2)
Possible causes (3) (5) Do not apply voltage
and standard value between (1) (2)
2) Disconnect connectors R14.
Disconnection in wiring har- Wiring harness between fuse BT-3 Voltage between R14
ness (female) (5) chassis 20 30 V
2 (12) R14 (female) (5)
(Disconnection or defective ground
contact) 1) Turn the starting switch OFF.
Wiring harness between BRC2 (1), (12) R14
Resistance Max. 1 z
(female) (5)
Between BRC2 (1), (12) chassis ground Voltage 20 30 V
HD465-7, HD605-7 20-717

(10)
20-718 HD465-7, HD605-7

(1)
[DB13KK] DIRECT POWER SOURCE LINE OF RETARDER CONTROLLER BATTERY:

LOWERING OF SOURCE/INPUT VOLTAGE (KK)
Action code Failure code Controller code Direct power source line of retarder controller battery: Lowering of
Trouble
E03 DB13KK BK source/input voltage (KK)
Contents of trouble The direct power source voltage is below 5 V.
Problem that
appears on machine
Related information If the fuse is broken, check the line between the fuse BRC1 (female) (7) for grounding fault.

Resistance Max. 1 z
Disconnection in wiring har- (16) chassis ground
1
(Disconnection or defective 2) Disconnect connector BRC1.
Possible causes contact) 3) Insert T-adapter.
in normal state Wiring harness between battery, Voltage between
battery relay terminal B, BRC1 BRC1 (9), (17) (8), 20 30 V
(7) (16)
Between BRC1 (7) (8), (16) Voltage 20 30 V
HD465-7, HD605-7 20-719

(10)
TROUBLESHOOTING [DB19KM]
[DB19KM] RETARDER CONTROLLER WIRING HARNESS: MISTAKE IN OPERATION

OR SETTING (KM)
Action code Failure code Controller code Retarder controller wiring harness: Mistake in operation or setting
Trouble (KM)
E03 DB19KM BK (Mistake in connection or defect in wiring harness)
The connector check signal, that is input when the starting switch is turned to the ON position, does
Contents of trouble
not agree with setting in the controller.
The controller turns the all output circuits OFF.
Problem that
ASR)
appears on machine
Failure codes (DB12KK, DHU2KX, DHU3KX) are displayed, too.

The connector of the connector check signal is connected normally.
1 aConnector check signal connector: BRC3A (1) (OPEN), BRC5A (1)
nector
(CLOSE)
Disconnection in wiring har- 2) Disconnect connector BRC5A.
2
Wiring harness between BRC5A (female) (1)
chassis ground
and standard value 2) Disconnect connector BRC3A.
3
Wiring harness between BRC3A
BRC3A (female) (1) Min. 1 M z
chassis ground
4 Retarder controller
Resistance Max. 1 z
chassis ground
Between BRC3A (female) (1) chassis ground Resistance Min. 1 M z
20-720 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DB1SKQ]
[DB1SKQ] WRONG INFORMATION ON MODEL SELECTION: DISAGREEMENT OF

Action code Failure code Controller code Wrong information on model selection: Disagreement of model selec-
Trouble
E03 DB1SKQ BK tion signals (KQ)
Since communication with the transmission controller (S-NET) is defective, model selection informa-
Contents of trouble
tion cannot be received or received model selection information is out of setting.
Problem that
appears on machine
Related information Other failures are detected, too. (Failure codes [DAFSKQ], [DAQAKR], [DAQSKQ] are displayed.)

Possible causes Transmission controller de- aIf the failure is not repaired by replacing the retarder controller, the
1
and standard value fective transmission controller is defective.
in normal state aIf the failure is repaired by replacing the transmission controller, the
retarder controller is defective.
HD465-7, HD605-7 20-721

(10)
TROUBLESHOOTING [DDD7KX]
[DDD7KX] FAILURE IN TRAVEL SPEED SET SWITCH SYSTEM (IF EQUIPPED): OUT
OF INPUT SIGNAL RANGE (KX)
Action code Failure code Controller code Failure in travel speed set switch system (if equipped): Out of in-
Trouble put signal range (KX)
E03 DDD7KX BK (When ARSC is set and ARSC system switch is ON)
Contents of trouble The input signal circuit voltage of the travel speed set switch is below 0.15 V.
Action of controller When ARSC operates, the controller releases the brake gradually.
Problem that
appears on machine

2) Replace the travel speed set switch (ARSC SET switch).
Travel speed set switch (AR-
1 Replace the travel Failure is not repaired. Switch is normal
SC SET switch) defective
speed set switch (AR-
SC SET switch). Failure is repaired. Switch is defective
2) Disconnect connector RE3.
2 Register (250 z) defective 3) Connect T-adapter.
Between RE3 (female) (1) (2) Resistance 250 25 z
3 Resistor (1,020 z) defective 3) Connect T-adapter.
Between RE4 (female) (1) (2) Resistance 1,020 102 z
2) Disconnect connectors BRC3A, BRC3B, ARC, RE3, and RE4.
Disconnection in wiring har- RE3 (male) (1) Resistance Max. 1 z
ness
Possible causes 4 Wiring harness between BRC3B (female) (15)
and standard value RE3 (male) (2) ARC (female) (1)
contact)
in normal state Wiring harness between RE4 (male) (1) ARC
Resistance Max. 1 z
(female) (3)
Wiring harness between RE4 (male) (2) ARC
Resistance Max. 1 z
(female) (2)
2) Disconnect connectors BRC3A and BRC3B.
Between BRC3A (6) (16) Voltage Approx. 5 V
5 Retarder controller defective 3) Insert T-adapter.
When set switch is ON Resistance 1,020 102 z
When set switch is
Resistance 68 6.8 z
Between BRC3B (fe- TOUCH UP
male) (15) BRC3A When set switch is
(female) (16) Resistance 198 19.8 z
TOUCH DOWN
When set switch is
Resistance 418 41.8 z
CANCEL
20-722 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DDD7KX]
HD465-7, HD605-7 20-723

(1)
TROUBLESHOOTING [DDD8KA]
[DDD8KA] ARSC SYSTEM SWITCH SYSTEM: DISCONNECTION (KA)

Action code Failure code Controller code ARSC system switch system: Disconnection (KA)
Trouble
E03 DDD8KA BK (When ARSC is set and ARSC system switch is ON)
Contents of trouble The ON input of the ARSC system switch is OFF and the OFF input of the system switch is OFF.
Problem that
appears on machine
Related information

Disconnection in wiring har- 2) Disconnect connectors ARSC and DPC2B.
1
Wiring harness between DPC2B (female) (1)
ARSC (female) (3)
2) Replace the ARSC system switch with normal one.
ARSC system switch defec- 3) Turn the starting switch ON.
2
Possible causes tive When the ARSC system No System switch is normal
and standard value switch is replaced with nor-
in normal state mal one, is failure repaired? Yes System switch is defective
2) Disconnect connector DPC1.
3 Machine monitor defective 5) Turn the starting switch ON.
Turn the ARSC system
switch ON (Press it up).
DPC2B (1)
chassis ground Turn the ARSC system
Voltage Max. 1 V
switch OFF (Press it down).
20-724 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DDD8KB]
[DDD8KB] ARSC SYSTEM SWITCH SYSTEM: SHORT CIRCUIT (KB)

Action code Failure code Controller code ARSC system switch system: Short circuit (KB)
Trouble
E03 DDD8KB BK (When ARSC is set and ARSC system switch is ON)
Contents of trouble The ON input of the ARSC system switch is OFF and the OFF input of the system switch is OFF.
Problem that
appears on machine
Related information

2) Disconnect connectors ARSC and DPC2B.
Wiring harness be- Voltage between
tween DPC2B (fe- DPC2B (female) (1),
Voltage Max. 1 V
male) (1) ARSC ARSC (female) (3)
2) Replace the ARSC system switch with normal one.
Possible causes ARSC system switch defec- 3) Turn the starting switch ON.
2
and standard value tive When the ARSC system No System switch is normal
in normal state switch is replaced with nor-
mal one, is failure repaired? Yes System switch is defective
Turn the ARSC system
switch ON (Press it up).
DPC2B (1)
chassis ground Turn the ARSC system Voltage Max. 1 V
switch OFF (Press it down).
HD465-7, HD605-7 20-725

(10)
TROUBLESHOOTING [dGR2L8]
[dGR2L8] FAILURE IN RETARDER OIL TEMPERATURE SENSOR SYSTEM: *SEE

SEPARATE LIST (L8)
Action code Failure code Controller code Failure in retarder oil temperature sensor system: *See separate
Trouble list (L8)
E03 dGR2L8 BK (When ARSC is set and the ARSC system switch is ON)
Contents of trouble The signal circuit voltage of the retarder brake oil temperature sensor is below 0.75 V.
Problem that
appears on machine
Related information
When ARSC is not set or the ARSC system switch is OFF, failure code "DGR2L8" is displayed.

Retarder brake oil tempera-
1 Brake oil temperature:
ture sensor defective Resistance 37 50 k z
Between T02 (male) 25C
(1) (2) Brake oil temperature:
Resistance 3.5 4.0 k z
100C
Possible causes 2) Disconnect connectors BRC3B and T02.
and standard value Ground fault in wiring har- 3) Connect T-adapter.
in normal state 2
ness Wiring harness between Resistance between BRC3B
BRC3B (female) (3) T02 (female) (3), T02 (female) Min. 1 M z
3 Retarder controller defective Brake oil temperature:
Between BRC3B (fe- Resistance 37 50 k z
25C
male) (3) BRC3A (fe-
Brake oil temperature:
male) (16) Resistance 3.5 4.0 k z
100C
20-726 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DGR2L8]
[DGR2L8] BRAKE OIL TEMPERATURE SENSOR (REAR): *SEE SEPARATE LIST (L8)
Action code Failure code Controller code Brake oil temperature sensor (Rear): *See separate list (L8)
Trouble
E01 DGR2L8 BK (When ARSC is set and the ARSC system switch is OFF)
Contents of trouble The signal circuit voltage of the retarder brake oil temperature sensor is below 0.75 V.
Problem that
appears on machine
Related information
When ARSC is set or the ARSC system switch is ON, failure code "dGR2L8" is displayed.

ture sensor defective Resistance 37 50 k z
Resistance 3.5 4.0 k z
100C
Possible causes 2) Disconnect connectors BRC3B and T02.
and standard value Ground fault in wiring har- 3) Connect T-adapter.
in normal state 2
BRC3B (female) (3) T02 (female) (3), T02 (female) Min. 1 M z
Between BRC3B (fe- Resistance 37 50 k z
25C
Brake oil temperature:
male) (16) Resistance 3.5 4.0 k z
100C
HD465-7, HD605-7 20-727

(10)
TROUBLESHOOTING [dHP4KX]
[dHP4KX] FAILURE IN SUSPENSION PRESSURE SENSOR (FR) SYSTEM

(IF EQUIPPED): OUT OF INPUT SIGNAL RANGE (KX)
Action code Failure code Controller code Failure in suspension pressure sensor (FR) system (if equipped):
Trouble Out of input signal range (KX)
E03 dHP4KX BK (When ARSC is set and the ARSC system switch is ON)
Contents of trouble The input signal circuit voltage of the suspension pressure sensor (Right) is below 1.0 V or above 4.6 V.
Problem that
appears on machine
This failure can be checked in the monitoring function (Code: 32802, 32803)
Related information
When ARSC is not set or the ARSC system switch is OFF, failure code "DHP4KX" is displayed.

2) Disconnect connectors, BRC3A, SUFR and PM6.
Disconnection in wiring har- Wiring harness between BRC3A (female) (20)
1 SUFR (female) (C)
SUFR (female) (A)
Wiring harness between PM6 (female) (2)
Resistance Max. 1 z
SUFR (female) (B)
2) Disconnect connectors BRC3A SUFR and PM6.
Wiring harness between Resistance between BRC3A
2 BRC3A (female) (20) (female) (20), SUFR (female) Min. 1 M z
ness
SUFR (female) (C) (C) chassis ground
Wiring harness between Resistance between PM6
PM6 (female) (2) SUFR (fe- (female) (2), SUFR (female) Min. 1 M z
Possible causes male) (B) (B) chassis ground
in normal state 2) Disconnect connectors BRC3A and SUFR.
Wiring harness between Voltage between BRC3A (fe-
BRC3A (female) (20) male) (9), SUFR (female) Max. 1 V
2) Disconnect connector SUFR.
Suspension pressure sensor 4) Connect the connector.
4
(FR) defective 5) Turn the starting switch ON.
Between SUFR (B) (A) Voltage 20 30 V
Between SUFR (C) (A) Voltage 1.0 4.6 V
2) Disconnect connectors BRC3A.
Between BRC3A (20) (16) Voltage 1.0 4.6 V
20-728 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-729

(5)
TROUBLESHOOTING [DHP4KX]
[DHP4KX] FAILURE IN SUSPENSION PRESSURE SENSOR (FR) SYSTEM

Action code Failure code Controller code Failure in suspension pressure sensor (FR) system (if equipped):
E03 DHP4KX BK (When ARSC is not set or the ARSC system switch is OFF)
Contents of trouble The input signal circuit voltage of the suspension pressure sensor (Right) is below 1.0 V or above 4.6 V.
Action of controller Auto suspension system does not operate.
Problem that
appears on machine
Related information
When ARSC is set and the ARSC system switch is ON, failure code "dHP4KX" is displayed.

2) Disconnect connectors, BRC3A, SUFR and PM6.
1 SUFR (female) (C)
SUFR (female) (A)
Resistance Max. 1 z
SUFR (female) (B)
2) Disconnect connectors BRC3A, SUFR and PM6.
2 BRC3A (female) (20) (female) (20), SUFR (female) Min. 1 M z
ness
PM6 (female) (2) SUFR (female) (2), SUFR (female) Min. 1 M z
Possible causes (female) (B) (B) chassis ground
in normal state 2) Disconnect connectors BRC3A and SUFR.
BRC3A (female) (20) male) (9), SUFR (female) Max. 1 V
4
2) Disconnect connectors BRC3A.
BRC3A (20) (16) Voltage 1.0 4.6 V
20-730 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-731

(5)
[dHP5KX] FAILURE IN SUSPENSION PRESSURE SENSOR (FL) SYSTEM

Action code Failure code Controller code Failure in suspension pressure sensor (FL) system (if equipped):
E03 dHP5KX BK (When ARSC is set and the ARSC system switch is ON)
Contents of trouble The input signal circuit voltage of the suspension pressure sensor (Left) is below 1.0 V or above 4.6 V.
Problem that
appears on machine
Related information
When ARSC is not set or the ARSC system switch is OFF, failure code "DHP5KX" is displayed.

2) Disconnect connectors, BRC3A, SUFL and PM6.
1 SUFL (female) (C)
SUFL (female) (A)
Resistance Max. 1 z
SUFL (female) (B)
2) Disconnect connectors BRC3A SUFL and PM6.
2 BRC3A (female) (19) (female) (19), SUFL (female) Min. 1 M z
ness
SUFL (female) (C) (C) chassis ground
PM6 (female) (2) SUFL (female) (2), SUFL (female) Min. 1 M z
in normal state 2) Disconnect connectors BRC3A and SUFL.
BRC3A (female) (20) male) (9), SUFL (female) (C) Max. 1 V
SUFL (female) (C) chassis ground
2) Disconnect connector SUFL.
4
Between SUFL (B) (A) Voltage 18 3 V
Between SUFL (C) (A) Voltage 1.0 4.6 V
BRC3A (19) (16) Voltage 1.0 4.6 V
20-732 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-733

(5)
[DHP5KX] FAILURE IN SUSPENSION PRESSURE SENSOR (FL) SYSTEM

Action code Failure code Controller code Failure in suspension pressure sensor (FL) system (if equipped):
E03 DHP5KX BK (When ARSC is not set or the ARSC system switch is OFF)
Contents of trouble The input signal circuit voltage of the suspension pressure sensor (Left) is below 1.0 V or above 4.6 V.
Action of controller ARSC does not operate.
Problem that
appears on machine
Related information
When ARSC is set and the ARSC system switch is ON, failure code "dHP5KX" is displayed.

2) Disconnect connectors, BRC3A, SUFL and PM6.
1 SUFL (female) (C)
SUFL (female) (A)
Resistance Max. 1 z
SUFL (female) (B)
2) Disconnect connectors BRC3A, SUFL and PM6.
2 BRC3A (female) (19) (female) (19), SUFL (female) Min. 1 M z
ness
PM6 (female) (2) SUFL (female) (2), SUFL (female) Min. 1 M z
in normal state 2) Disconnect connectors BRC3A and SUFL.
BRC3A (female) (20) male) (9), SUFL (female) (B) Max. 1 V
SUFL (female) (C) chassis ground
4
(FL) defective 5) Turn the starting switch ON.
BRC3A (19) (16) Voltage 1.0 4.6 V
20-734 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-735

(5)
TROUBLESHOOTING [DHU2KX]
[DHU2KX] ACCUMULATOR OIL PRESSURE SENSOR (FRONT): OUT OF INPUT

SIGNAL RANGE (KX)
Action code Failure code Controller code Accumulator oil pressure sensor (Front): Out of input signal
Trouble
E01 DHU2KX BK range (KX)
Contents of trouble The signal circuit voltage of the front accumulator oil pressure sensor is below 0.5 V or above 4.5 V.
Problem that
appears on machine

2) Disconnect connector BRC1 and fuse BT3 terminal (12).
4) Connect the connector and fuse BT3 terminal (12).
Voltage between
Wiring harness between fuse BT3
BRC1 (5) chassis 20 30 V
terminal(12) BRC1 (female) (5)
Disconnection in wiring har- ground
1
(Disconnection or defective 2) Disconnect connectors BRC1, BRC3A, and ACCF.
Resistance Max. 1 z
ACCF (female) (C)
Resistance Max. 1 z
ACCF (female) (A)
Resistance Max. 1 z
ACCF (female) (B)
2) Disconnect connectors BRC3B and ACCF.
2 BRC3A (female) (9) ACCF (female) (9), ACCF (female) Min. 1 M z
(female) (C) (C) chassis ground
and standard value
in normal state Wiring harness between Resistance between BRC1
BRC1 (female) (14) ACCF (female) (3), ACCF (female) Min. 1 M z
(female) (B) (B) chassis ground
2) Disconnect connectors BRC3A and ACCF.
BRC3A (female) (9) ACCF male) (9), ACCF (female) Max. 1 V
2) Disconnect connector ACCF.
Front accumulator oil pres- 4) Connect the connector.
4
Between ACCF (B) (A) Voltage 20 30 V
Between ACCF (C) (A) Voltage 0.5 4.5 V
2) Disconnect connectors BRC1 and BRC3A.
Between BRC1 (14) BRC3A (16) Voltage 20 30 V
BRC3A (9) (16) Voltage 0.5 4.5 V
20-736 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-737

(1)
[DHU3KX] ACCUMULATOR OIL PRESSURE SENSOR (REAR): OUT OF INPUT SIGNAL

RANGE (KX)
Action code Failure code Controller code Accumulator oil pressure sensor (Rear): Out of input signal
Trouble
E01 DHU3KX BK range (KX)
Contents of trouble The signal circuit voltage of the rear accumulator oil pressure sensor is below 0.5 V or above 4.5 V.
Problem that
appears on machine

2) Disconnect connector BTC1 and fuse BT3 terminal (12).
4) Connect the connector and fuse BT3 terminal (12).
Voltage between
Wiring harness between fuse BT3
BRC1 (5) chassis 20 30 V
Disconnection in wiring har- terminal (12) BRC1 (female) (5) ground
1
(Disconnection or defective 2) Disconnect connectors BRC1, BRC3A, and ACCR.
Resistance Max. 1 z
ACCR (female) (C)
Resistance Max. 1 z
ACCR (female) (A)
Resistance Max. 1 z
ACCR (female) (B)
2) Disconnect connectors BRC3B and ACCR.
2 BRC3A (female) (10) (female) (10), ACCR (fe- Min. 1 M z
ACCR (female) (C) male) (C) chassis ground
and standard value
BRC1 (female) (14) ACCR (female) (3), ACCR (female) Min. 1 M z
2) Disconnect connectors BRC3A and ACCR.
BRC3A (female) (10) male) (10), ACCR (female) Max. 1 V
ACCR (female) (C) (C) chassis ground
2) Disconnect connector ACCR.
Rear accumulator oil pres- 4) Connect the connector.
4
Between ACCR (B) (A) Voltage 20 30 V
Between ACCR (C) (A) Voltage 0.5 4.5 V
2) Disconnect connectors BRC1 and BRC3A.
Between BRC1 (14) BRC3A (16) Voltage 20 30 V
BRC3A (10) (16) Voltage 0.5 4.5 V
20-738 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-739

(1)
TROUBLESHOOTING [dK11KX]
[dK11KX] FAILURE IN ACCELERATION SENSOR SYSTEM (IF EQUIPPED): OUT OF

INPUT SIGNAL RANGE (KX)
Action code Failure code Controller code Failure in acceleration sensor system (if equipped): Out of input
Trouble signal range (KX)
E03 dK11KX BK (When ARSC is set and the ARSC system switch is ON)
Contents of trouble The signal circuit voltage of the acceleration sensor is below 0.6 V or above 4.7 V.
Problem that
appears on machine
If the failure code "DK11KX" related to the transmission controller is displayed, perform troubleshooting
Related information for it first.
When ARSC is not set or the ARSC system switch is OFF, failure code "DK11KX" is displayed.

Disconnection in wiring har- 2) Disconnect connectors BRC3B and ATC3B.
1
Wiring harness between BRC3B (female) (11)
ATC3B (female) (11)
2) Disconnect connectors BRC3B and ATC3B.
and standard value 2 Resistance between
ness Wiring harness between BRC3B
BRC3B (female) (11),
in normal state (female) (11) ATC3B (female) Min. 1 M z
ATC3B (female) (11)
(11)
chassis ground
Between BRC3B (female) (11) chassis
Voltage 0.6 4.75 V
ground
20-740 HD465-7, HD605-7

(10)
[DK11KX] FAILURE IN ACCELERATION SENSOR SYSTEM (IF EQUIPPED): OUT OF

INPUT SIGNAL RANGE (KX)
Action code Failure code Controller code Failure in acceleration sensor system (if equipped): Out of input
Trouble signal range (KX)
E03 DK11KX BK (When ARSC is not set or the ARSC system switch is OFF)
Contents of trouble The signal circuit voltage of the acceleration sensor is below 0.6 V or above 4.7 V.
Action of controller ARSC does not operate.
Problem that
appears on machine
If the failure code "dK11KX" related to the transmission controller is displayed, perform troubleshooting
Related information for it first.
When ARSC is set and the ARSC system switch is ON, failure code "dK11KX" is displayed.

Disconnection in wiring har- 2) Disconnect connectors BRC3B and ATC3B.
1
ATC3B (female) (11)
2) Disconnect connectors BRC3B and ATC3B.
and standard value 2 Resistance between
ness Wiring harness between BRC3B
BRC3B (female) (11),
in normal state (female) (11) ATC3B (female) Min. 1 M z
ATC3B (female) (11)
(11)
chassis ground
Between BRC3B (female) (11) chassis
Voltage 0.6 4.75 V
ground
HD465-7, HD605-7 20-741

(10)
TROUBLESHOOTING [DK51L5]
[DK51L5] RETARDER LEVER POTENTIOMETER: *SEE SEPARATE LIST (L5)

Trouble Retarder lever potentiometer: *See separate list (L5)
E03 DK51L5 BK
The signal voltage of the potentiometer of the retarder lever circuit is below 0.3 V or above 4.7 V. Or,
Contents of trouble
the potentiometer signal does not agree with the switch signal.
The controller acts as follows, depending on the condition of the failure.
Controls with the potentiometer signal.
Limits the output for the solenoid to 70%.
Turns the output for the solenoid OFF.
The following appear, depending on the action of the controller.
Problem that This failure does not have a serious effect on the machine.
appears on machine The retarder cannot control finely.
The retarder does not operate (The foot brake operates, however).

2) Disconnect connectors BRC2, BRC3A, BRC3B, BRC5A, RE1, and RTL.
Resistance Max. 1 z
RE1 (female) (1)
Wiring harness between RE1 (female) (2)
Resistance Max. 1 z
RTL (female) (1)
1 RTL (female) (3)
RTL (female) (2)
Resistance Max. 1 z
RTL (female) (4)
Resistance Max. 1 z
RTL (female) (5)
Wiring harness between RTL (female) (6)
Resistance Max. 1 z
chassis ground
2) Disconnect connectors BRC3B, and RE1, and RTL.
and standard value
BRC2 (female) (16) RE1 (female) (16), RE1 (female) Min. 1 M z
2
ness Wiring harness between Resistance between RE1
RE1 (female) (2) RTL (fe- (female) (2), RTL (female) Min. 1 M z
male) (1) (1) chassis ground
Wiring harness between Resistance between BRC3B
BRC3B (female) (16) RTL (female) (16), RTL (female) Min. 1 M z
2) Disconnect connectors BRC3B and RTL.
Wiring harness between Voltage between BRC2 (fe-
BRC2 (female) (16) RE1 male) (16), RE1 (female) (1) Max. 1 V
3 Hot short in wiring harness (female) (1) chassis ground
Wiring harness between Voltage between RE1 (fe-
RE1 (female) (2) RTL (female) (2), RTL (female) (1) Max. 1 V
male) (1) chassis ground
Wiring harness between Voltage between BRC3B (fe-
BRC3B (female) (16) RTL male) (16), RTL (female) (2) Max. 1 V
20-742 HD465-7, HD605-7

(10)

4 Resistor (RE1) defective 3) Connect T-adapter.
Between RE1 (male) (1) (2) Resistance 250 z
2) Disconnect connector RTL
4) Insert the connector.
6) Check the potentiometer.
Between RTL (1) (3) Voltage 4.1 4.8 V
Between RTL (2) (3) Voltage 0.3 4.7 V
5 Retarder lever defective 2) Disconnect connector RTL
Between RTL (male) Lever at OFF position Resistance Max. 1 z

(4) (6) Lever at ON position Resistance Min. 1 M z
Possible causes
and standard value
in normal state Between RTL (male) Lever at OFF position Resistance Min. 1 M z
(5) (6) Lever at ON position Resistance Max. 1 z
2) Disconnect connectors BRC2, BRC3A, and BRC3B.
Between BRC2 (16) BRC3A (16) Voltage 4.1 4.8 V
Between BRC3B (16) BRC3A (16) Voltage 0.3 4.7 V
6 Retarder controller defective 2) Disconnect connector RTL.
Between BRC5A (fe- Lever at OFF position Resistance Max. 1 z
male) (6) chassis
ground Lever at ON position Resistance Min. 1 M z
Between BRC5A (fe- Lever at OFF position Resistance Min. 1 M z
male) (7) chassis
ground Lever at ON position Resistance Max. 1 z
HD465-7, HD605-7 20-743

(10)
20-744 HD465-7, HD605-7

(1)
[DK52KX] DUMP LEVER POTENTIOMETER 1: OUT OF INPUT SIGNAL RANGE (KX)

Action code Failure code Controller code Dump lever potentiometer 1: Out of input signal range (KX)
Trouble
E03 DK52KX BK (Out of input signal range of lever potentiometer 1 or 2)
Contents of trouble The signal voltage of the signal circuit of dump lever potentiometer 1 or 2 is below 0.3 V or above 4.7 V.
Action of controller The controller recognizes the dump lever position as "HOLD".
Problem that
The dump body does not operate.
appears on machine

2) Disconnect connectors BRC3A, BRC3B, and HSL.
Disconnection in wiring har- HSL (female) (4) Resistance Max. 1 z
ness
1 Wiring harness between BRC3B (female) (14)
HSL (female) (2)
contact)
Resistance Max. 1 z
HSL (female) (3)
Resistance Max. 1 z
HSL (female) (1)
BRC3A (female) (6) HSL (female) (6), HSL (female) Min. 1 M z
2
BRC3B (female) (14) HSL (female) (14), HSL (female) Min. 1 M z
Possible causes Wiring harness between Resistance between BRC3B
and standard value BRC3B (female) (12) HSL (female) (12), HSL (female) Min. 1 M z
in normal state (female) (3) (3) chassis ground
BRC3A (female) (6) HSL male) (6), HSL (female) (4) Max. 1 V
3 Hot short in wiring harness (female) (4) chassis ground
BRC3B (female) (14) HSL male) (14), HSL (female) (2) Max. 1 V
BRC3B (female) (12) HSL male) (12), HSL (female) (3) Max. 1 V
2) Disconnect connector HSL.
4 Dump lever defective 5) Turn the starting switch ON.
Between HSL (4) (1) Voltage 4.6 5.4 V
HD465-7, HD605-7 20-745

(10)

in normal state 5 Retarder controller defective 5) Turn the starting switch ON.
20-746 HD465-7, HD605-7

(10)
[DK53L8] DUMP LEVER POTENTIOMETER 2: *SEE SEPARATE LIST (L8)
Action code Failure code Controller code Dump lever potentiometer 2: *See separate list (L8)
Trouble (Out of total range of input signal voltage of lever potentiometer
E03 DK53L8 BK 1 or 2)
Contents of trouble The total voltage of the signal circuit of dump lever potentiometer 1 or 2 is below 4.4 V or above 5.6 V.
Action of controller The controller recognizes the dump lever position as "NEUTRAL".
Problem that
appears on machine
This failure can be checked in the monitoring function (Code: 34300, 34301).
Related information
If the failure code "DK52KX" is displayed, perform troubleshooting for it.

2) Disconnect connector HSL.
Possible causes
1 Dump lever defective 5) Turn the starting switch ON.
and standard value
in normal state Between HSL (4) (1) Voltage 4.6 5.4 V
If the failure is not repaired by performing the troubleshooting in 1
above, the retarder controller is defective.
HD465-7, HD605-7 20-747

(10)
[DK54KX] BODY POSITIONER SENSOR: OUT OF INPUT SIGNAL RANGE (KX)

Action code Failure code Controller code Body positioner sensor: Out of input signal range (KX)
Trouble
E03 DK54KX BK (Out of input signal range of lever potentiometer 1 or 2)
Contents of trouble The signal circuit voltage of the body positioner is below 0.3 V or above 4.7 V.
The controller controls dumping according to the dump level signal.
The controller controls, assuming that the body is not seated.
Body seating shocks become large.
Problem that The dump lever positioner does not function.
appears on machine The maximum gear speed is limited.
The machine cannot travel in reverse if the dump lever is not at FLOAT.
Related information This failure can be checked in the monitoring function (Code: 34300, 34301, 34400, 34600).

2) Disconnect connectors BRC3A, BRC3B, and B07.
Disconnection in wiring har- Wiring harness between BRC3A (female)(6)
1 B07 (female) (C)
B07 (female) (B)
Resistance Max. 1 z
B07 (female) (A)
2 BRC3A (female) (6) B07 (female) (6), B07 (female) Min. 1 M z
ness
BRC3B (female) (13) B07 (female) (13), B07 (female) Min. 1 M z
Possible causes 2) Disconnect connectors BRC3A, BRC3B, and B07.
and standard value 3) Connect T-adapter.
BRC3A (female) (6) B07 male) (6), B07 (female) (C) Max. 1 V
(female) (C) chassis ground
BRC3B (female) (13) B07 male) (13), B07 (female) (B) Max. 1 V
(female) (B) chassis ground
2) Disconnect connector B07.
4 Body positioner defective 4) Connect the connector.
Between B07 (C) (A) Voltage 4.6 5.4 V
Between B07 (B) (A) Voltage 0.3 4.7 V
20-748 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-749

(1)
TROUBLESHOOTING [DKD0L6]
[DKD0L6] FAILURE IN STEERING SPEED SENSOR (IF EQUIPPED): *SEE SEPARATE

LIST (L6)
Action code Failure code Controller code Failure in steering speed sensor (if equipped): *See separate list
Trouble
E01 DKD0L6 BK (L6)
Disconnection, grounding fault, or short circuit occurs in the signal circuit of the steering speed sensor
Contents of trouble
and no signals are input.
Problem that
appears on machine

2) Disconnect connectors BRC2, BRC3A, and SR2.
1 SR2 (female) (2)
SR2 (female) (3)
Resistance Max. 1 z
SR2 (female) (1)
2) Disconnect connectors BRC2, BRC3A, and SR2.
2 BRC3A (female) (14) SR2 (female) (14), SR2 (female) Min. 1 M z
ness
BRC2 (female) (14) SR2 (female) (14), SR2 (female) Min. 1 M z
2) Disconnect connector SR2.
6) Turn the steering wheel slowly.
Steering speed sensor de- Between SR2 (1) (3) Voltage 10 13 V
3
fective
Between SR2 (2) (3) Voltage See FIG-1.
Between BRC2 (14) (21) Voltage 10 13 V
4 Retarder controller defective 1) Turn the starting switch OFF.
6) Turn the steering wheel slowly.
Between BRC3A (12) (14) Voltage See FIG-1.
20-750 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DKD0L6]
HD465-7, HD605-7 20-751

(1)
TROUBLESHOOTING [dLt3KA]
[dLt3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTION (KA)
Action code Failure code Controller code Transmission output shaft speed sensor: Disconnection (KA)
Trouble
E01 dLt3KA BK (When ARSC is set and ARSC system switch is ON)
The signal circuit of the transmission output shaft speed sensor is disconnected and no signals are
Contents of trouble
input.
Problem that
appears on machine
Related information
When ARSC is not set or the ARSC system switch is OFF, failure code "dLT3KA" is displayed.

aFor details, see TESTING AND ADJUSTING, "Adjustment of
sensor
transmission speed sensor".
2
Possible causes Between CN5 (male) (1), (2) chassis ground Resistance Min. 1 M z
in normal state 2) Disconnect connectors BRC3A and CN5.
ness
3 Wiring harness between BRC3A (female) (13)
CN5 (female) (1)
contact)
Resistance Max. 1 z
CN5 (female) (2)
2) Disconnect connectors BRC3A and ATC3A.
4 Retarder controller defective 3) Connect T-adapter.
Between BRC3A (female) (13) (14) Resistance 500 1,000 z
20-752 HD465-7, HD605-7

(10)
TROUBLESHOOTING [dLT3KA]
[dLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTION (KA)
Action code Failure code Controller code Transmission output shaft speed sensor: Disconnection (KA)
Trouble
E03 dLT3KA BK (When ARSC is not set or ARSC system switch is OFF)
The signal circuit of the transmission output shaft speed sensor is disconnected and no signals are
Contents of trouble
input.
Problem that
appears on machine
Related information
When ARSC is set and the ARSC system switch is ON, failure code "dLT3KA" is displayed.

aFor details, see TESTING AND ADJUSTING, "Adjustment of
sensor
transmission speed sensor".
2
Possible causes Between CN5 (male) (1), (2) chassis ground Resistance Min. 1 M z
in normal state 2) Disconnect connectors BRC3A and CN5.
ness
CN5 (female) (1)
contact)
Resistance Max. 1 z
CN5 (female) (2)
2) Disconnect connectors BRC3A and ATC3A.
HD465-7, HD605-7 20-753

(10)
TROUBLESHOOTING [DW35KZ]
[DW35KZ] FAILURE IN OUTPUT SYSTEM OF AUTO SUSPENSION SOLENOID 1 (IF

EQUIPPED) (DISCONNECTION, GROUNDING FAULT, SHORT CIRCUIT):
Action code Failure code Controller code Failure in output system of auto suspension solenoid 1 (if
Trouble equipped) (Disconnection, grounding fault, short circuit): Discon-
E01 DW35KZ BK nection or short circuit (KZ)
When the output to the auto suspension solenoid 1 circuit is ON, a too large current flows or any current
Contents of trouble
does not flow. Or, some current is flowing while the output is OFF.
Action of controller The controller turns the output to auto suspension solenoid 1 OFF.
Problem that
The auto suspension system does not operate.
appears on machine

2) Disconnect connector S04.
Auto suspension solenoid 1 3) Insert T-adapter.
1
defective Between S04 (female) (1) (2) Resistance 15 35 z
Between S04 (female) (1), (2) chassis
ground
Possible causes
2) Disconnect connectors BRC1 and S04.
2 Wiring harness between BRC1 (female) (1)
S04 (female) (1)
contact)
Wiring harness between S04 (female) (2)
Resistance Max. 1 z
chassis ground
Between BRC1 (female) (1) chassis ground Resistance 15 20 z
20-754 HD465-7, HD605-7

(10)
[DW36KZ] FAILURE IN OUTPUT SYSTEM OF AUTO SUSPENSION SOLENOID 2 (IF

EQUIPPED) (DISCONNECTION, GROUNDING FAULT, SHORT CIRCUIT):
Action code Failure code Controller code Failure in output system of auto suspension solenoid 2 (if
Trouble equipped) (Disconnection, grounding fault, short circuit): Discon-
E01 DW36KZ BK nection or short circuit (KZ)
When the output to the auto suspension solenoid 2 circuit is ON, a too large current flows or any current
Contents of trouble
does not flow. Or, some current is flowing while the output is OFF.
Action of controller The controller turns the output to auto suspension solenoid 2 OFF.
Problem that
The auto suspension system does not operate.
appears on machine

2) Disconnect connector S05.
Auto suspension solenoid 2 3) Insert T-adapter.
1
defective Between S05 (female) (1) (2) Resistance 15 35 z
Between S05 (female) (1), (2) chassis
ground
Possible causes
2) Disconnect connectors BRC1 and S05.
S05 (female) (1)
contact)
Wiring harness between S05 (female) (2)
Resistance Max. 1 z
chassis ground
HD465-7, HD605-7 20-755

(10)
[DW72KZ] FAILURE IN KICK-OUT SOLENOID OUTPUT SYSTEM (D_OUT3)

(DISCONNECTION, GROUNDING FAULT, SHORT CIRCUIT):
Action code Failure code Controller code Failure in kick-out solenoid output system (D_OUT3) (Discon-
Trouble nection, grounding fault, short circuit): Disconnection or short cir-
E01 DW72KZ BK cuit (KZ)
When the output to the dump lever kick-out solenoid circuit is ON, a too large current flows or any cur-
Contents of trouble
rent does not flow. Or, some current is flowing while the output is OFF.
Action of controller The controller turns the output to the dump lever kick-out solenoid OFF.
Problem that
Detent lock is not applied to the dump lever.
appears on machine

2) Disconnect connectors BRC1 and LK0.
ness
1 Wiring harness between LK0 (female) (2)
chassis ground
contact)
Resistance Max. 1 z
LK0 (female) (1)
2) Disconnect connectors BRC1 and LK0.
and standard value Voltage between
in normal state Wiring harness between BRC1 BRC1 (female) (11),
Max. 1 V
(female) (11) LK0 (female) (1) LK0 (female) (1)
chassis ground
2) Disconnect connector LK0.
Dump lever kick-out sole- 3) Connect T-adapter.
3
noid defective
Between LK0 (male) (1) (2) Resistance 39 z 5%
Between LK0 (male) (1), (2) chassis ground Resistance Min. 1 M z
2) Disconnect connector LK0.
Between BRC1 (female) (11) chassis ground Resistance 39 z 5%
20-756 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-757

(1)
[DW73KZ] FAILURE IN HOIST SELECT VALVE OUTPUT SYSTEM (D_OUT5)

(DISCONNECTION, GROUNDING FAULT, SHORT CIRCUIT):
Action code Failure code Controller code Failure in hoist select valve output system (D_OUT5) (Discon-
Trouble nection, grounding fault, short circuit): Disconnection or short cir-
E03 DW73KZ BK cuit (KZ)
When the output to the dump lever select valve solenoid circuit is ON, a too large current flows or any
Contents of trouble
current does not flow. Or, some current is flowing while the output is OFF.
The controller turns the output to the dump lever select valve solenoid OFF.
The controller turns the output to the dump lever EPC valve solenoid OFF.
Problem that
appears on machine

2) Disconnect connectors BRC1 and HSOL.
ness
1 Wiring harness between HSOL (female) (B)
chassis ground
contact)
Resistance Max. 1 z
HSOL (female) (A)
2) Disconnect connectors BRC1 and HSOL.
Possible causes 2 Hot short in wiring harness
Voltage between
and standard value
Wiring harness between BRC1 BRC1 (female) (12),
in normal state Max. 1 V
(female) (12) HSOL (female) (A) HSOL (female) (A)
chassis ground
2) Disconnect connector HSOL.
Dump lever select valve so- 3) Connect T-adapter.
3
lenoid defective Between HSOL (male) (A) (B) Resistance 15 35 z
Between HSOL (male) (A), (B) chassis
ground
2) Disconnect connector HSOL.
20-758 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-759

(1)
TROUBLESHOOTING [DK11K4]
[DK11K4] PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE OF REAR

WHEEL: UNCONTROLLABLE (K4)
Action code Failure code Controller code Proportional solenoid pressure reducing valve of rear wheel: Un-
Trouble
E03 DK11K4 BK controllable (K4)
Contents of trouble The proportional solenoid pressure reducing valve does not return (does not move).
Action of controller Resets the retarder solenoid output.
Problem that
The retarder (rear brake), ARSC, and overrun prevention system do not operate.
appears on machine
The state of the retarder oil pressure switch can be checked with the monitoring function
Related information
(Code: 34100).

Defective proportional
Check proportional solenoid pressure reducing valve of rear wheel
1 solenoid pressure reducing
and repair or replace it, if it has abnormality (mechanical failure).
valve of rear wheel
1) Turn starting switch OFF.
2) Disconnect connector RESW.
Defective retarder oil pres- 4) Connect connector.
2
sure switch 5) Turn starting switch ON.
Between RESW (fe- Oil pressure ON Resistance Max. 1 z
male) (1) (2) Oil pressure OFF Resistance Min. 1 M z
2) Disconnect connector BRC5A and RESW.
Ground fault in wiring har- 4) Connect connector.
3 5) Turn starting switch ON.
ness
Possible causes
and standard value Wiring harness between Resistance between BRC5A
in normal state BRC5A (female) (4) (female) (4), RESW (female) Max. 1 z
RESW (female) (1) (1) chassis ground
4 Hot short in wiring harness 5) Turn starting switch ON.
BRC5A (female) (4) male) (4), RESW (female) Max. 1 V
5 Defective retarder controller 4) Connect connector.
5) Turn starting switch ON.
Between BRC5A (4) Oil pressure ON Voltage Max. 1 V
shassis ground Oil pressure OFF Voltage 20 30 V
20-759-1 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DK11K4]
HD465-7, HD605-7 20-759-2

(5)
TROUBLESHOOTING [DX11KA]
[DX11KA] DISCONNECTION IN OUTPUT CIRCUIT OF PROPORTIONAL SOLENOID

PRESSURE REDUCING VALVE OF REAR WHEEL (A_OUT2):
DISCONNECTION (KA)
Action code Failure code Controller code Disconnection in output circuit of electromagnetic proportional
Trouble pressure reducing valve of rear wheel (A_OUT2): Disconnection
E03 DX11KA BK (KA)
When the output to the rear wheel pressure reducing valve solenoid circuit is ON, any current does not
Contents of trouble
flow.
Action of controller The controller turns the output to the rear brake pressure reducing valve solenoid OFF.
Problem that
The retarder (rear brake) does not operate.
appears on machine
Related information This failure can be checked in the monitoring function (Code: 33800, 33801).

2) Disconnect connector RETV.
Rear brake pressure reduc- 3) Insert T-adapter.
1
ing valve solenoid defective Between RETV (female) (1) (2) Resistance 10 30 z
Between RETV (female) (1), (2) chassis
ground
Possible causes
2) Disconnect connectors BRC2 and RETV.
RETV (female) (1).
contact)
Resistance Max. 1 z
RETV (female) (2).
2) Disconnect connector BRC.
Between BRC2 (female) (7) (17) Resistance 10 30 z
20-760 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DX11KB]
[DX11KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF PROPORTIONAL SOLENOID

PRESSURE REDUCING VALVE OF REAR WHEEL (A_OUT2): SHORT
CIRCUIT (KB)
Action code Failure code Controller code Short circuit in output circuit of electromagnetic proportional
Trouble pressure reducing valve of rear wheel (A_OUT2): Short circuit
E03 DX11KB BK (KB)
When the output to the rear wheel pressure reducing valve solenoid circuit is ON, a too large current
Contents of trouble
flows.
Problem that
appears on machine

1
ground
2) Disconnect connectors BRC2 and RETV.
and standard value Resistance between
in normal state Grounding fault or short cir- Wiring harness between BRC2 BRC2 (female) (9),
2 Min. 1 M z
cuit in wiring harness (female) (7) RETV (female) (1). RETV (female) (1)
chassis ground.
Wiring harness between BRC2 (female) (7) RETV (fe-
male) (1) and between BRC (female) (17) RETV (female) Min. 1 M z
(2)
HD465-7, HD605-7 20-761

(10)
TROUBLESHOOTING [DX11KY]
[DX11KY] GROUNDING FAULT IN OUTPUT CIRCUIT OF PROPORTIONAL SOLENOID

PRESSURE REDUCING VALVE OF REAR WHEEL (A_OUT2): SHORT
CIRCUIT WITH POWER SOURCE LINE (KY)
Action code Failure code Controller code Grounding fault in output circuit of electromagnetic proportional
Trouble pressure reducing valve of rear wheel (A_OUT2): Short circuit
E03 DX11KY BK with power source line (KY)
While the output to the rear wheel pressure reducing valve solenoid circuit is OFF, some current is flow-
Contents of trouble
ing.
Problem that
appears on machine

1
ground

and standard value 2) Disconnect connectors BRC2 and RETV.
2 Hot short in wiring harness Voltage between
Max. 1 V
(female) (7) RETV (female) (1). RETV (female) (1)
chassis ground.
20-762 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DX11MA]
[DX11MA] PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE OF REAR

WHEEL: MALFUNCTION (MA)
Action code Failure code Controller code Proportional solenoid pressure reducing valve of rear wheel:
Trouble
E03 DX11MA BK Malfunction (MA)
Contents of trouble The proportional solenoid pressure reducing valve does not operate (does not move).
Action of controller Resets the retarder solenoid output.
Problem that
The retarder (rear brake), ARSC, and overrun prevention system do not operate.
appears on machine
The state of the retarder oil pressure switch can be checked with the monitoring function
Related information
(Code: 34100).

Defective proportional sole- Check the proportional solenoid pressure reducing valve of rear
1 noid pressure reducing wheel and repair or replace it, if it has abnormality (mechanical fail-
valve of rear wheel ure).
2) Disconnect connector RESW.
Defective retarder oil pres- 4) Connect connector.
2
sure switch 5) Turn starting switch ON.
Between RESW (fe- Oil pressure ON Resistance Max. 1 z
male) (1) (2) Oil pressure OFF Resistance Min. 1 M z
Possible causes
and standard value 1) Turn starting switch OFF.
in normal state 2) Disconnect connector BRC5A RESW.
3
ness Wiring harness between Resistance between BRC5A
BRC5A (female) (4) (female) (4), RESW (female) Max. 1 z
Between BRC5A (4) Oil pressure ON Voltage Max. 1 V
chassis ground (16) Oil pressure OFF Voltage 20 30 V
HD465-7, HD605-7 20-762-1

(10)
[DX13KA] DISCONNECTION IN OUTPUT CIRCUIT OF HOIST EPC VALVE (A_OUT3):

DISCONNECTION (KA)
Action code Failure code Controller code Disconnection in output circuit of hoist EPC valve (A_OUT3):
Trouble
E03 DX13KA BK Disconnection (KA)
Contents of trouble When the output to the dump EPC solenoid circuit is ON, any current does not flow.
The controller turns the output to the dump select valve solenoid OFF.
The controller turns the output to the dump EPC valve solenoid OFF.
Problem that
appears on machine

2) Disconnect connector HEPC.
Dump EPC valve solenoid
1
defective Between HEPC (female) (1) (2) Resistance 15 20 z
Between HEPC (female) (1), (2) chassis
ground
Possible causes
2) Disconnect connectors BRC2 and HEPC.
and standard value
in normal state
ness
HEPC (female) (1).
contact)
Resistance Max. 1 z
HEPC (female) (1).
19. Between BRC2 (female) (10) (20) Resistance 15 20 z
HD465-7, HD605-7 20-763

(10)
[DX13KB] GROUNDING FAULT IN OUTPUT CIRCUIT OF HOIST EPC VALVE (A_OUT3):

SHORT CIRCUIT (KB)
Action code Failure code Controller code Grounding fault in output circuit of hoist EPC valve (A_OUT3):
Trouble Short circuit (KB)
E03 DX13KB BK
Contents of trouble When the output to the dump EPC valve solenoid circuit is ON, a too large current flows.
Action of controller The controller turns the output to the dump EPC valve solenoid OFF.
Problem that
appears on machine

Dump EPC valve solenoid
1 Between HEPC (female) (1) (2) Resistance 15 20 z
defective
ground
and standard value
Resistance between
in normal state
Grounding fault or short cir- Wiring harness between BRC2 BRC2 (female) (10),
Min. 1 M z
2 (female) (10) HEPC (female) (1). HEPC (female) (1)
cuit in wiring harness
chassis ground.
Wiring harness between BRC2 (female) (10) HEPC (fe-
male) (1) and between BRC2 (female) (20) HEPC (fe- Min. 1 M z
male) (2)
20-764 HD465-7, HD605-7

(10)
[DX13KY] SHORT CIRCUIT IN OUTPUT CIRCUIT OF HOIST EPC VALVE (A_OUT3):

SHORT CIRCUIT WITH POWER SOURCE LINE (KY)
Action code Failure code Controller code Short circuit in output circuit of hoist EPC valve (A_OUT3): Short
Trouble
E03 DX13KY BK circuit with power source line (KY)
Contents of trouble While the output to the dump EPC valve solenoid circuit is OFF, some large current is flowing.
The controller turns the output to the dump EPC valve solenoid OFF.
Problem that
appears on machine

Dump EPC valve solenoid 3) Insert T-adapter.
1
defective Between HEPC (female) (1) (2) Resistance 15 20 z
ground
and standard value Voltage between
in normal state Hot short in wiring harness
2 (Contact with power source Max. 1 V
(female) (10) HEPC (female) (1). HEPC (female) (1)
wiring harness)
chassis ground.
Voltage between
Max. 1 V
(female) (20) HEPC (female) (2). HEPC (female) (2)
chassis ground.
HD465-7, HD605-7 20-765

(10)
20-766 HD465-7, HD605-7

(1)
TROUBLESHOOTING BK-1
BK-1 PARKING BRAKE DOES NOT OPERATE NORMALLY

a) When the parking brake switch is set in the OFF position, the parking brake is not released
Action code Failure code Controller code Parking brake does not operate normally
Trouble a) When the parking brake switch is set in the OFF position, the
Not set Not set BK parking brake is not released
Contents of trouble When the parking brake switch is set in the OFF position, the parking brake is not released.
Problem that
When the parking brake switch is set in the OFF position, the parking brake is not released.
appears on machine
Before performing the troubleshooting, check that fuse (BT4) (4) is not broken. (If the fuse is broken,
Related information check its wiring harness for grounding fault.)

Parking brake switch
When parking brake switch (R33) No
(R33) is normal
is disconnected, does parking
brake operate? Parking brake switch
Yes
(R33) is defective
Parking brake switch defec- 3) Connect T-adapter.
1
tive Set the parking brake switch
Between R33 in PARK.
(male) (1) (2) Set the parking brake switch
Resistance Max. 1 z
in OFF.
Set the parking brake switch
Resistance Max. 1 z
in OFF.
2) Disconnect connector PSOL
Parking brake solenoid de- 3) Connect T-adapter.
2
fective Between PSOL (male) (1) (2) Resistance 30 50 z
Between PSOL (male) (1), (2) chassis
Possible causes Resistance Min. 1 M z
and standard value ground
Relay (R19) is
No
When parking brake safety relay (R19) is normal
replaced, is failure repaired? Relay (R19) is
Yes
defective
3) Check the relay.
Parking brake safety relay
(R19) defective
3) Check the relay.
Apply 24 V between
Resistance Max. 1 z
tween (1) (2).
Apply 24 V between
Resistance Max. 1 z
tween (1) (2).
HD465-7, HD605-7 20-767

(10)

2) Disconnect connectors R19, R33, PSOL, fuse BT4 (4).
Wiring harness between fuse BT4 (4) R19
Possible causes Disconnection in wiring har- (female) (5), R33 (female) (3) Resistance Max. 1 z
4 Wiring harness between R19 (female) (1), (3)
in normal state (Disconnection or defective Resistance Max. 1 z
R33 (female) (1)
contact)
Resistance Max. 1 z
PSOL (female) (1)
Wiring harness between PSOL (female) (2)
Resistance Max. 1 z
chassis ground
20-768 HD465-7, HD605-7

(10)
b) When the parking brake switch is set in the PARK position, the parking brake does not work
Action code Failure code Controller code Parking brake does not operate normally
Trouble b) When the parking brake switch is set in the PARK position, the
Not set Not set Not set parking brake does not work
Contents of trouble When the parking brake switch is set in the PARK position, the parking brake does not work.
Problem that
When the parking brake switch is set in the PARK position, the parking brake does not work.
appears on machine

Parking brake switch defec- (male) (1) (2)
1 Set the parking brake switch
tive Resistance Max. 1 z
in OFF.
Resistance Max. 1 z
in OFF.
Relay (R19) is
No
When parking brake safety relay (R19) is normal
replaced, is failure repaired? Relay (R19) is
Yes
defective

and standard value 2) Disconnect connector R19.
in normal state 3) Check the relay.
Parking brake safety relay
(R19) defective
3) Check the relay.
Apply 24 V between
Resistance Max. 1 z
tween (1) (2).
Apply 24 V between
Resistance Max. 1 z
tween (1) (2).
2) Disconnect connectors R33 and PSOL.
3 Hot short in wiring harness Voltage between R33
Wiring harness between R33 (fe- (female) (2), PSOL (fe-
Max. 1 z
male) (2) PSOL (female) (1) male) (1) chassis
ground
HD465-7, HD605-7 20-769

(10)
20-770 HD465-7, HD605-7

(1)
BK-2 RETARDER BRAKE OIL TEMPERATURE GAUGE DOES NOT OPERATE

NORMALLY
Action code Failure code Controller code Retarder brake oil temperature gauge does not operate normally
Trouble
Not set Not set Not set (When ARSC is not set or ARSC system switch is OFF)
Contents of trouble The signal circuit voltage of the retarder brake oil temperature gauge is below 0.75 V.
Problem that This failure does not have a serious effect on the machine.
appears on machine When ARSC is set or the ARSC system switch is ON, failure code "dGR2L8" is displayed.

ture gauge defective Resistance 37 50 kz
Resistance 3.5 4.0 kz
100C
2) Disconnect connectors BRC3B and T02.
and standard value 4) Turn the starting switch ON.
in normal state 2 Hot short in wiring harness
Voltage between
Wiring harness between BRC3B BRC3B (female) (3),
Max. 1 V
chassis ground
Between BRC3B (fe- Resistance 37 50 kz
25C
male) (16) Brake oil temperature:
Resistance 3.5 4.0 kz
100C
HD465-7, HD605-7 20-771

(10)
BK-3 INCLINATION ALARM IS TURNED ON WHEN DUMP BODY IS RAISED

(WHEN MACHINE IS NOT INCLINED MORE THAN 15)
Action code Failure code Controller code Inclination alarm is turned ON when dump body is raised
Trouble
Not set Not set Not set (When machine is not inclined more than 15)
The inclination alarm is turned ON when the dump body is raised while the machine is not inclined
Contents of trouble
more than 15)
Problem that The inclination alarm is turned ON when the dump body is raised while the machine is not inclined
appears on machine more than 15)
If the inclination alarm is turned ON while the machine is incline more than 15, it is not defective (it is
Related information normal).

1 Inclination sensor defective
Inclination is below 15 Resistance Max. 1 z
Between SR3 (male)
Inclination is 15 or
(1) (2) Resistance Min. 1 M z
more
Possible causes Disconnection in wiring har- 2) Disconnect connectors BRC5A and SR3.
SR3 (female) (1)
Between BRC5A (fe- Inclination is below 15 Resistance Max. 1 z
male) (12) chassis Inclination is 15 or
ground Resistance Min. 1 M z
more
20-772 HD465-7, HD605-7

(10)
BK-4 TOUCH UP/DOWN AND CANCELLATION CANNOT BE PERFORMED
Action code Failure code Controller code Touch up/down and cancellation cannot be performed.
Trouble
Not set Not set Not set (When ARSC is set and ARSC system switch is ON)
Contents of trouble Touch up/down and cancellation cannot be performed.
Problem that
Touch up/down and cancellation cannot be performed.
appears on machine
Related information If failure code "DDD7KX" is displayed, perform troubleshooting for it.

2) Replace the travel speed set switch (ARSC SET switch).
Travel speed set switch (AR-
1 Replace the travel Failure is not repaired. Switch is normal
SC SET switch) defective
speed set switch (AR-
SC SET switch). Failure is repaired. Switch is defective

2 Register (250 z) defective 3) Connect T-adapter.
Between RE3 (female) (1) (2) Resistance 250 25 z
3 Resistor (1,020 z) defective 3) Connect T-adapter.
Between RE4 (female) (1) (2) Resistance 1,020 102 z

Disconnection in wiring har- 2) Disconnect connectors BRC3A, ARC, and RE4.
Possible causes ness 3) Connect T-adapter.
4
and standard value (Disconnection or defective
in normal state contact) Resistance Max. 1 z
ARC (female) (3)
4) Connect the connectors.
Between BRC3A (6) (16) Voltage Approx. 5 V
5 Retarder controller defective 2) Disconnect connectors BRC3A and BRC3B.
When set switch is ON Resistance 1,020 102 z
Between BRC3B When set switch is TOUCH
Resistance 68 6.8 z
(female) (15) UP
BRC3A (female) When set switch is TOUCH
(16) Resistance 198 19.8 z
DOWN
When set switch is CANCEL Resistance 418 41.8 z
HD465-7, HD605-7 20-773

(10)
20-774 HD465-7, HD605-7

(1)
TROUBLESHOOTING FOR PAYLOAD
METER SYSTEM (CARD TYPE)
(LC MODE)
Electrical system diagram related to payload meter.................................................................................... 20-802

Service codes of payload meter (card type) and contents of self-diagnosis ....................................... 20-804
Information in troubleshooting table........................................................................................................ 20-807
Phenomenon code table ......................................................................................................................... 20-808
LC- 1 When starting switch is turned ON, any item is not displayed .................................................... 20-809
LC- 2 After starting switch is turned ON, all external pilot lamps do not light up .................................. 20-811
LC- 3 External lamps light up while condition for lighting is not set...................................................... 20-814
LC- 4 Lighting level of external pilot lamps is abnormal ....................................................................... 20-816
LC- 5 Cycle data and engine ON/OFF data not recorded
(charge level signal system: judges that engine is stopped) ...................................................... 20-818
LC- 6 Calibration cannot be performed and displayed clock does not conform to condition
(shift lever "N" position signal system)........................................................................................ 20-819
LC- 7 Displayed logic is abnormal........................................................................................................ 20-821
a) When loaded dump truck starts traveling, "0" is kept displayed............................................ 20-821
b) After loaded dump truck start traveling, display of odometer does not increase................... 20-821
c) When travel speed exceeds limit speed, "SP:SP" does not go off........................................ 20-821
d) Integrated pay load is not displayed ..................................................................................... 20-822
e) Displayed and saved pay load is not correct ........................................................................ 20-823
LC- 8 Payload meter keeps displaying "b:FL" (body "FLOAT" signal system: dump lever is not in
"FLOAT" position while truck is not dumping)............................................................................. 20-824
LC- 9 Payload meter displays "F:09" (lowering of internal backup battery voltage) ............................. 20-826
LC-10 Payload meter displays " :FULL" (data saving memory is full) ................................................ 20-826
LC-11 Payload meter displays "F-20" : failure in power source of suspension pressure sensor and
clinometer system....................................................................................................................... 20-827
LC-12 Payload meter displays "F-21" "F-24" : disconnection or grounding fault in suspension
sensor signal system .................................................................................................................. 20-829
LC-13 Payload meter displays "F-25" "F-28" : short circuit with power source (Hot short)
in suspension sensor signal system ........................................................................................... 20-832
LC-14 Payload meter displays "F-CAL" (negligence of calibration or internal damage of payload meter) ... 20-834
LC-15 Payload meter displays "F:43" "F:45" (short circuit with power source (Hot short)
in external pilot lamp relay system) ............................................................................................ 20-835
LC-16 Payload meter displays "L-bad" (cycle data were saved while truck body was pitching) ........... 20-837
LC-17 External pilot lamp indicates forecast while truck is not being loaded or clock is displayed
while truck travels for 160 m after it is loaded ............................................................................ 20-839
LC-18 Payload meter displays "F-31" : grounding fault or disconnection in clinometer sensor signal
system ........................................................................................................................................ 20-840
LC-19 Payload meter displays "F-32" : short circuit with power source in clinometer sensor signal
system ........................................................................................................................................ 20-842
LC-20 Payload meter displays "F:18" (disconnection in charge level signal system) ........................... 20-844
HD465-7, HD605-7 20-801

(10)
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED TO PAYLOAD METER
ELECTRICAL SYSTEM DIAGRAM RELATED TO PAYLOAD METER
20-802 HD465-7, HD605-7

(2)
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED TO PAYLOAD METER
HD465-7, HD605-7 20-803

(2)
SERVICE CODES OF PAYLOAD METER (CARD TYPE)
TROUBLESHOOTING AND CONTENTS OF SELF-DIAGNOSIS
SERVICE CODES OF PAYLOAD METER (CARD TYPE) AND CONTENTS OF SELF-

DIAGNOSIS
The following are displayed on the display unit of Payload Meter (Card type). (They are not displayed on the
monitor panel.)
Priority of
display Contents Service code External pilot lamps
b-FL lighting up All lighting up

Dump lever is not in FLOAT position (Truck is not
1
dumping)
b-FL lighting up
2 Memory card is not inserted Cd flashing
3 Backup battery voltage is lowered F-09 flashing
Cycle data memory is FULL
Engine ON/OFF data is FULL

4 See (*1) on next
page.
Abnormality warning data memory is FULL
Data memory of integrated pay load and total number
of cycle is FULL
5 Disconnection of terminal R F-18 flashin All flashing
6 Abnormality in sensor power source (18 V) F-20 flashin All flashing
7 Short circuit with chassis ground or disconnection in F-21 flashin All flashing
front left suspension pressure sensor system
Short circuit with chassis ground or disconnection in
8 F-22 flashin All flashing
front right suspension pressure sensor system
9 Short circuit with chassis ground or disconnection in F-23 flashin All flashing
rear left suspension pressure sensor system
Short circuit with chassis ground or disconnection in
10 rear right suspension pressure sensor system F-24 flashin All flashing
Short circuit with power source in front left suspension
11 pressure sensor system F-25 flashin All flashing
Short circuit with power source in front right suspension
pressure sensor system
13 Short circuit with power source in rear left suspension F-27 flashin All flashing
pressure sensor system
Short circuit with power source in rear right suspension
14 pressure sensor system F-28 flashin All flashing
Short circuit with chassis ground or disconnection in cli-
nometer system
16 Short circuit with power source of clinometer system F-32 flashin All flashing
Calibration has not been performed or RAM is abnor-
17 F CAL flashin All flashing
mal
Related lamps
18 Short circuit in external pilot lamp G relay F-43 flashin While stopped: Kept lighted up
While traveling: Turned OFF
19 Short circuit in external pilot lamp Y relay F-44 flashin Other lamps
While loading: Normal operation
While stopped without loading:
20 Short circuit in external pilot lamp R relay F-45 flashin Flashing
While traveling: Turned OFF
Pay load in cycle data is inaccurate [See (*2) in page
21 L. bad flashin
20-806]
22 Higher than limit speed SP : SP flashin
F-71 flashin
F-73 flashin
F-80 flashin
F-81 flashin
F-91 flashin
23 Communication defective or wrong option code setting F-92 flashin
F-93 flashin
F-94 flashin
F-95 flashin
F-96 flashin
F-97 flashin
F-98 flashin
20-804 HD465-7, HD605-7

(1)
(*1) Alarm displayed when memory is FULL abnormality/warning data are deleted
1. Cycle data from the oldest one. (The alarm of "2)"
1) If the number of saved cycles reaches above is maintained.)
2600 (the remaining capacity is 300
cycles or less), the following is repeated. 4. Integrated pay load/Total number of
L : FUL flashes 7 times. cycles data
: flashes 1 time. 1) If the total number of cycles reaches
2) If the number of saved cycles reaches 9994 (the remaining capacity is 5 cycles
2900 (the remaining capacity is 0 cycle), or less) or the difference between the
the following is repeated. saved integrated pay load and 999900
L : FUL lights up (for 3 seconds). tons (upper limit) becomes 5 times the
: flashes 1 time. rated hauling capacity, the following is
3) If the number of saved cycles exceeds repeated.
2900, the new cycles are saved as H : FUL flashes 7 times (for 3 seconds).
2901st cycle, 2902nd cycle ---. Each : flashes 1 time.
time the new cycle is saved, however, 2) If the total number of cycles reaches
the cycle data are deleted from the oldest 9997 (the remaining capacity is 2 cycles
one. (The alarm of "2)" above is main- or less) or the difference between the
tained.) saved integrated pay load and 999900
tons (upper limit) becomes 5 times the
2. Engine ON/OFF data rated hauling capacity, the following is
1) If the number of saved ON/OFF times repeated.
reaches 105 (the remaining capacity is H : FUL lights up (for 3 seconds).
10 times or less), the following is : flashes 1 time.
repeated 2 times and then goes off. 3) If the total number of cycles reaches
E : FUL flashes 7 times (for 3 seconds). 9999 or the saved integrated pay load
: flashes 1 time. exceeds 999900 tons, both of the inte-
2) If the number of saved ON/OFF times grated pay load and total number of
reaches 115 (the remaining capacity is 0 cycles are cleared to 0, and then they are
time), the following is repeated 2 times integrated again. (The display unit dis-
and then goes off. plays the operating time normally again.)
E : FUL lights up (for 3 seconds).
: flashes 1 time. 5. For the method of resetting the data in 1 3
3) If the number of saved ON/OFF times above when they become FULL, see "8.3
exceeds 115, the new ON/OFF times are Operator check mode" in the instruction
saved as 116th time, 117th time ---. manual for Payload Meter (Card type).
Each time the new ON/OFF time is Once the data in 4 becomes FULL, it is not
saved, however, the engine ON/OFF reset until it is cleared to 0 automatically. For
data are deleted from the oldest one. the method of clearing this data to 0 forcibly
before it becomes FULL, see "8.2 Forcible
3. Abnormality/Warning data display of integrated pay load/total number of
1) If the number of saved abnormalities/ cycles" in the instruction manual for Payload
warnings reaches 220 (the remaining Meter .
capacity is 10 abnormalities/warnings or
less), the following is repeated. 6. As for the order of display, any priority is not
E : FUL flashes 7 times (for 3 seconds). given to the items in 1 4 above. If multiple
: flashes 1 time. data become FULL simultaneously, they are
2) If the number of saved abnormalities/ displayed while the dump truck is not being
warnings reaches 230 (the remaining loaded.
capacity is 0 abnormality/warning), the
following is repeated.
E : FUL lights up (for 3 seconds).
: flashes 1 time.
3) If the number of saved abnormalities/
warnings exceeds 230, the new abnor-
malities/warnings are saved as 231st
abnormality/warning, 232nd abnormality/
warning ---. Each time the new abnor-
mality/warning is saved, however, the
HD465-7, HD605-7 20-805

(1)
(*2) Inaccurate pay load in cycle data

1. The payload meter constantly senses the
pay load by the signals from the suspension
pressure sensor. The sensed pay load
becomes a little inaccurate during and just
after loading because of the dynamic friction
of the suspension. To save the pay load
more accurately, the payload meter senses
and saves the pay load just before dumping
after the dynamic friction of the suspension
during loading is canceled by loaded travel.
(The payload meter saves the payload meter
as a part of the cycle data.)
2. Accordingly, if the load is dumped (if the

dump lever is operated) before pitching of
the machine body stops, the payload meter
may save the pay load inaccurately.
3. When the dump truck is braked sharply or

stopped by chocks in the dumping place, the
pay load may be saved inaccurately.
4. If the load is dumped before the dump truck

stops pitching for the above reasons, the
payload meter displays "Inaccurate pay load
in cycle data" in the abnormality/warning
items list to call the operator's attention. The
pay load sensed in this case is saved, how-
ever.
20-806 HD465-7, HD605-7

(1)

panel panel panel
Problem that
appears on machine

Remarks on judgment
1
Disconnection
Ground fault
Short circuit
indicate priority)
side.
side.
5
side.
HD465-7, HD605-7 20-807

(10)


code code

input

sistency
source (Hot short)
cuit
MW Sliding
NS Overheat
20-808 HD465-7, HD605-7

(10)
TROUBLESHOOTING LC-1
LC-1 WHEN STARTING SWITCH IS TURNED ON, ANY ITEM IS NOT DISPLAYED

Trouble When starting switch is turned ON, any item is not displayed
Not set Not set Not set
Contents of trouble When the starting switch is turned ON, any item is not displayed.
Problem that
When the starting switch is turned ON, any item is not displayed.
appears on machine
Before performing the troubleshooting, check that fuse BT2 (12) circuit breaker (80 A) is not broken.
Related information
(If the fuse is broken, check its wiring harness for grounding fault.)

When LC GDL relay (R10) is re- No Relay (R10) is normal
placed, is failure repaired? Yes Relay (R10) is defective
3) Check the relay.
1 LC GDL relay (R10) defective Between R10 (male) (5) (6) Resistance 200 400 z
3) Check the relay.
4) Apply voltage between R10 (male) (1) (2)
Apply 24 V between
Resistance Max. 1 z
Possible causes (3) (5) Do not apply 24 V be-
and standard value Resistance Min. 1 M z
tween (1) (2).
in normal state
2) Disconnect connector connectors R10 and fuse BT2 (12).
Wiring harness between battery relay terminal
Disconnection in wiring har- M, fuse BT2 (12) R10 (female) (1), (5) Resistance Max. 1 z
ness
2 Wiring harness between R10 (female) (2)
chassis ground
contact)
Resistance Max. 1 z
R10 (female) (3)
Resistance Max. 1 z
chassis ground
2) Disconnect connector PM5.
3 Payload meter defective 4) Connect the connector.
Between PM5 (1) (13) Voltage 20 30 V
HD465-7, HD605-7 20-809

(10)
20-810 HD465-7, HD605-7

(1)
LC-2 AFTER STARTING SWITCH IS TURNED ON, ALL EXTERNAL PILOT LAMPS DO
NOT LIGHT UP
Action code Failure code Controller code After starting switch is turned ON, all external pilot lamps do not
light up
Trouble
Not set Not set Not set (Perform troubleshooting with shift lever in N and starting switch
in ON)
After starting switch is turned ON, all external pilot lamps do not light up. (Perform troubleshooting with
Contents of trouble
shift lever in N and starting switch in ON.)
Problem that After starting switch is turned ON, all external pilot lamps do not light up. (Perform troubleshooting with
appears on machine shift lever in N and starting switch in ON.)
Check that any bulb is not broken.
If there is grounding fault between the fuse and shift lever switch terminal N (on the power supply side),
Related information failure code "DF10KA" related to the transmission controller is displayed.
Before performing the troubleshooting, check that fuse BT2 (14) is not broken. (If the fuse is broken,
check its wiring harness for grounding fault.)

1 Breakage of bulb Any bulb must not be broken.
When payload meter relay (R40) is No Relay (R40) is normal
replaced, is failure repaired? Yes Relay (R40) is defective
3) Check the relay.
Payload meter relay (R40) 1) Turn the starting switch OFF.

2 2) Disconnect connector R40.
defective
3) Check the relay.
4) Apply voltage between R40 (male) (5) (6)
Apply 24 V between
Resistance Max. 1 z
Possible causes tween (5) (6).
and standard value Apply 24 V between
tween (5) (6).
2) Disconnect connectors SF1, R40, PM5, R43, R44, R45, B1, B2, and
B3.
1) Any lamp does not light up.
Wiring harness between SF1 (female) (4)
Resistance Max. 1 z
R40 (female) (5)
ness Wiring harness between R40 (female) (6)
(Disconnection or defective chassis ground
contact) 2) Specific lamps do not light up.
Resistance Max. 1 z
R43 (female) (3)
Resistance Max. 1 z
R44 (female) (3)
Resistance Max. 1 z
R45 (female) (3)
HD465-7, HD605-7 20-811

(10)

Wiring harness between R43 (female) (6) G
Resistance Max. 1 z
(female) (1)
Wiring harness between R44 (female) (6) A
Resistance Max. 1 z
(female) (1)
Disconnection in wiring har- Wiring harness between R45 (female) (6) R
Resistance Max. 1 z
ness (female) (1)
3
(Disconnection or defective Wiring harness between B1 (female) (1)
chassis ground
Wiring harness between B2 (female) (1)
Resistance Max. 1 z
chassis ground
Wiring harness between B3 (female) (1)
Resistance Max. 1 z
chassis ground
2) Disconnect connectors SF1, R40, PM5, R43, R44, and R45.
1) Any lamp does not light up.
aIn this case, fuse BT3 (10) (for supplying power to shift switch N)
is broken.
Resistance between
Wiring harness between SF1 (fe- SF1 (female) (4), R40
Possible causes Min. 1 M z
and standard value male) (4) R40 (female) (5) (female) (5) chassis
in normal state ground
2) Specific lamps do not light up.
ness
Wiring harness between PM5 (fe- PM5 (female) (4), R43
Max. 1 z
male) (4) R43 (female) (2) (female) (2) chassis
ground
Resistance between
Max. 1 z
ground
Resistance between
Max. 1 z
ground
5 Payload meter defective 5) Turn the starting switch ON.
20-812 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-813

(1)
LC-3 EXTERNAL LAMPS LIGHT UP WHILE CONDITION FOR LIGHTING IS NOT SET

Trouble External lamps light up while condition for lighting is not set
Contents of trouble External lamps light up while condition for lighting is not set.
Problem that
External lamps light up while condition for lighting is not set.
appears on machine

2) Replace R43, R44, and R45 with normal ones.
(Replace only the defective relays with normal ones.)
When payload meter lamp relays Relays (R43), (R44),
No
(R43), (R44), and (R45) is re- and (R45) are normal
placed with normal ones respec- Relays (R43), (R44),
tively, is failure repaired? Yes
and (R45) are defective
Payload meter lamp relays 2) Disconnect connectors R43, R44, and R45.
1 (R43), (R44), and (R45) de- 3) Check the relays.
fective
Between R43, R44, and R45 (1) (2) Resistance 200 400 z
2) Disconnect connectors R43, R44, and R45.
3) Check the relays.
4) Apply voltage between R43, R44, and R45 (1) (2).
Apply 24 V between
Resistance Max. 1 z
Between R43, R44, (1) (2).
Possible causes and R45 (3) (6). Do not apply 24 V be-
and standard value Resistance Min. 1 M z
tween (1) (2).
in normal state
2) Disconnect connectors SF1, R40, R43, R44, and R45.
Voltage between SF1
Wiring harness between SF1 (fe- (female) (4), R40 (fe-
Max. 1 V
male) (4) R40 (female) (5) male) (5) chassis
ground
Voltage between PM5
Wiring harness between R40 (fe- (female) (4), R43 (fe-
2 Hot short in wiring harness Max. 1 V
male) (2), (4) R43 (female) (3) male) (2) chassis
ground
Voltage between PM5
Max. 1 V
ground
Voltage between PM5
Max. 1 V
ground
20-814 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-815

(1)
LC-4 LIGHTING LEVEL OF EXTERNAL PILOT LAMPS IS ABNORMAL

Trouble Lighting level of external pilot lamps is abnormal
Contents of trouble Lighting level of external pilot lamps is abnormal.
Problem that
Lighting level of external pilot lamps is abnormal.
appears on machine
Related information If this phenomenon is stopped by performing calibration again, it is not a failure.

4) Set the shift lever in N.
No
placed with normal ones respec- Relays (R43), (R44),
tively, is failure repaired? Yes
and (R45) are defective
Payload meter lamp relays 1) Turn the starting switch OFF.
1 (R43), (R44), and (R45) de- 2) Disconnect connectors R43, R44, and R45.
fective 3) Check the relays.
Between R43, R44, and R45 (1) (2) Resistance 200 400 z
Apply 24 V between
Resistance Max. 1 z
Between R43, R44, (1) (2).
and R45 (3) (6). Do not apply 24 V be-
tween (1) (2).
Possible causes
in normal state 2) Disconnect connectors PM5, R43, R44, and R45.
Disconnection in wiring har- Wiring harness between PM5 (female) (4)
2 R43 (female) (2)
R44 (female) (2)
Resistance Max. 1 z
R45 (female) (2)
2) Disconnect connectors R40, R43, R44, R45, G, A, and R.
Voltage between R43
Wiring harness between R43 (fe- (female) (6), G (fe-
Max. 1 V
male) (6) G (female) (1) male) (1) chassis
ground
3 Hot short in wiring harness Voltage between R44
Wiring harness between R44 (fe- (female) (6), A (fe-
Max. 1 V
male) (6) A (female) (1) male) (1) chassis
ground
Voltage between R45
Wiring harness between R45 (fe- (female) (6), R (fe-
Max. 1 V
male) (6) R (female) (1) male) (1) chassis
ground
20-816 HD465-7, HD605-7

(10)

in normal state 5 Payload meter defective 5) Turn the starting switch ON.
HD465-7, HD605-7 20-817

(10)
LC-5 CYCLE DATA AND ENGINE ON/OFF DATA NOT RECORDED

(CHARGE LEVEL SIGNAL SYSTEM: JUDGES THAT ENGINE IS STOPPED)
Action code Failure code Controller code Cycle data and engine ON/OFF data not recorded
Trouble
Not set Not set Not set (Charge level signal system: Judges that engine is stopped)
Cycle data and engine ON/OFF data not recorded. (Charge level signal system: Judges that engine
Contents of trouble
is stopped.)
Problem that Cycle data and engine ON/OFF data not recorded. (Charge level signal system: Judges that engine
appears on machine is stopped.)
Related information If the engine ON/OFF data are recorded, perform troubleshooting of LC-7.

Disconnection in wiring har- 3) Insert T-adapter.
1
(Disconnection or defective 5) Start the engine.
contact) 6) Depress the accelerator pedal more than "half".
Possible causes
Wiring harness between PM5 (fe- Voltage between PM5
and standard value Min. 5 V
male) (9) alternator terminal R (9) chassis ground
in normal state
6) Depress the accelerator pedal more than "half".
Between PM5 (9) chassis ground Voltage Min. 5 V
20-818 HD465-7, HD605-7

(10)
LC-6 CALIBRATION CANNOT BE PERFORMED AND DISPLAYED CLOCK DOES NOT

CONFORM TO CONDITION
(SHIFT LEVER "N" POSITION SIGNAL SYSTEM)
Action code Failure code Controller code Calibration cannot be performed and displayed clock does not
Trouble conform to condition
Not set Not set Not set (Shift lever "N" position signal system)
Calibration cannot be performed and displayed clock does not conform to condition. (Shift lever "N"
Contents of trouble
position signal system)
Problem that Calibration cannot be performed and displayed clock does not conform to condition. (Shift lever "N"
appears on machine position signal system)
Related information Check that the external pilot lamp operates as described in the operation manual.

When transmission neutral relay No Relay (R02) is normal
(R02) is replaced with normal one,
is failure repaired? Yes Relay (R02) is defective
Transmission neutral relay 3) Check the relays.
1
Apply 24 V between
Resistance Max. 1 z
tween (1) (2).
2) Disconnect connectors PM5 and R02.
Possible causes Disconnection in wiring har- Wiring harness between PM6 (female) (10)
and standard value
in normal state 2 R02 (female) (6)
Wiring harness between SF1 (female) (4)
R02 (female) (1)
Resistance Max. 1 z
chassis ground
2) Disconnect connectors BRC3B and PM3.
Resistance between
Wiring harness between PM6 (fe- PM6 (female) (10),
Ground fault in wiring har- Min. 1 M z
3 male) (10) R02 (female) (6) R02 (female) (6)
ness
chassis ground
Resistance between
Wiring harness between SF1 (fe- SF1 (female) (4), R02
Min. 1 M z
ground
Between PM6 When shift lever is N Voltage 20 30 V
(10) PM5 (13) When shift lever is not N Voltage Max. 1.5 V
HD465-7, HD605-7 20-819

(10)
20-820 HD465-7, HD605-7

(1)
LC-7 DISPLAYED LOGIC IS ABNORMAL

a) When loaded dump truck starts traveling, "0" is kept displayed.
b) After loaded dump truck start traveling, display of odometer does not increase.
c) When travel speed exceeds limit speed, "SP:SP" does not go off.
Action code Failure code Controller code Displayed logic is abnormal

a) When loaded dump truck starts traveling, "0" is kept displayed.
b) After loaded dump truck start traveling, display of odometer
Trouble
Not set Not set Not set does not increase.
c) When travel speed exceeds limit speed, "SP:SP" does not go
off.
When loaded dump truck starts traveling, "0" is kept displayed.
Contents of trouble After loaded dump truck start traveling, display of odometer does not increase.
When travel speed exceeds limit speed, "SP:SP" does not go off.
When loaded dump truck starts traveling, "0" is kept displayed.
Problem that
After loaded dump truck start traveling, display of odometer does not increase.
appears on machine
When travel speed exceeds limit speed, "SP:SP" does not go off.
If the pay load is displayed during loading but "0" is displayed after the dump truck starts traveling until
it dumps the load, the travel speed signal is not sensed.
Related information
If failure codes "DLT3KA" and "DLT3LC" related to transmission controller or failure codes "DLT3KA"
and "dLT3LC" related to retarder controller are displayed, perform troubleshooting for them first.

2) Disconnect connectors PM5 and R02.
ness
1 Wiring harness between PM5 (female) (7)
Possible causes (Disconnection or defective Resistance Max. 1 z
CN5 (female) (1)
and standard value contact)
CN5 (female) (2)
2 Payload meter defective 3) Connect T-adapter.
Wiring harness between PM5 (female) (7) (8) Resistance Max. 1 z
HD465-7, HD605-7 20-821

(10)
d) Integrated pay load is not displayed.

Trouble
Not set Not set Not set d) Integrated pay load is not displayed.
Contents of trouble Integrated pay load is not displayed.
Problem that
Integrated pay load is not displayed.
appears on machine
To display the integrated pay load, the following condition must be satisfied during the time from the
start to the end of dumping.
(1) When the load was dumped previous time, it was reduced to below 1/5 of the rated pay load within
5 minutes after the dump lever was changed from "LOWER" to "FLOAT".
Related information
(2) When the load was dumped previous time, "b-fl" was not displayed for 5 seconds just after the
dump lever was changed from "LOWER" to "FLOAT".
(3) The load to be dumped this time is above 1/2 of the rated pay load.
If the payload meter displays "b-fl", perform troubleshooting of LC-8.

and standard value
in normal state 1 If the payload meter displays "b-FL", perform troubleshooting of LC-8.
20-822 HD465-7, HD605-7

(10)
e) Displayed and saved pay load is not correct.

Trouble
Not set Not set Not set e) Displayed and saved pay load is not correct.
Contents of trouble Displayed and saved pay load is not correct.
Problem that
Displayed and saved pay load is not correct.
appears on machine
The error of the payload meter is 5%.
The possible causes of display of wrong displayed and saved values are as follows
(1) Defective setting of model selection switch of payload meter
(2) Defective adjustment of suspension
(3) Negligence of calibration of payload meter
Related information <Precautions>
i) If the load is dumped while the displayed pay load is changing because of pitching of the truck body,
the saved value may become inaccurate. Accordingly, dump after the displayed value is fixed.
ii) The pay load displayed in the loading place (just after loading) may be a little (1 - 5 t) less than that
displayed in the dumping place.
aFor details, see Operation Manual, 3. For higher accuracy.

LC display: "CO: X. X"
HD465-7 HD605-7
1 Wrong model setting
X. X
0. 7 0. A
display
i) When truck is empty
(1) Empty, (2) Flat place
aSee STRUCTURE AND OPERATION, Service Check Mode, (b)
Display of data for calculation of pay load.
Pressure difference between both sides
Possible causes 0.98 MPa {10 kg/cm2}
(Front)
and standard value
in normal state Pressure difference between both sides (Rear) 1.47 MPa {15 kg/cm2}
Improper suspension gas If the pressure difference exceeds the above range, adjust the sus-
2
pressure pension gas, referring to "Testing and adjusting suspension cylin-
der".
ii) When truck is loaded
Contact (Interference) of frame stopper and There must not be
rear axle housing contact (Interference)
iii)When truck turns on slope
Contact (Interference) of frame stopper and There must not be
rear axle housing contact (Interference)
3 Improper calibration Perform calibration according to the operation manual.
HD465-7, HD605-7 20-823

(10)
LC-8 PAYLOAD METER KEEPS DISPLAYING "b:FL"

(BODY "FLOAT" SIGNAL SYSTEM: DUMP LEVER IS NOT IN "FLOAT" POSITION
WHILE TRUCK IS NOT DUMPING)
Action code Failure code Controller code Payload meter keeps displaying "b:FL"
Trouble (Body "FLOAT" signal system: Dump lever is not in "FLOAT" po-
Not set Not set Not set sition while truck is not dumping)
Payload meter keeps displaying "b:FL" (Body "FLOAT" signal system: Dump lever is not in "FLOAT"
Contents of trouble
position while truck is not dumping)
Problem that Payload meter keeps displaying "b:FL" (Body "FLOAT" signal system: Dump lever is not in "FLOAT"
appears on machine position while truck is not dumping)
Check that failure codes "DK52KX", "DK53L8", and "DK24KX" (failure in dump lever system) related
Related information
to retarder controller are not displayed. If any of them is displayed, perform troubleshooting for it.

Disconnection in wiring har- 2) Disconnect connectors PM6 and BRC1.
1
BRC1 (female) (15)
2) Disconnect connectors PM6 and BRC1.
ness
Min. 1 M z
male) (9) BRC1 (female) (15) BRC1 (female) (15)
chassis ground
and standard value 2) Disconnect connector BRC1.
3 Retarder controller defective 5) Turn the starting switch ON.
Between BRC1 Dump lever is in "FLOAT". Voltage 20 30 V

(15) chassis Dump lever is out of
ground Voltage Max. 1 V
"FLOAT".
4 Payload meter defective 5) Turn the starting switch ON.
Between PM6 Dump lever is in "FLOAT". Voltage 20 30 V
(9) chassis Dump lever is out of
"FLOAT".
20-824 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-825

(1)
TROUBLESHOOTING LC-9, LC-10
LC-9 PAYLOAD METER DISPLAYS "F:09"

(LOWERING OF INTERNAL BACKUP BATTERY VOLTAGE)

Payload meter displays "F:09"
Payload meter Trouble
Not set Not set (Lowering of internal backup battery voltage)
displays "F:09"
Contents of trouble Payload meter displays "F:09" (Lowering of internal backup battery voltage)
Problem that
Payload meter displays "F:09" (Lowering of internal backup battery voltage)
appears on machine

and standard value Lowering of internal backup
in normal state 1 Replace the internal backup battery according to the operation manual.
battery voltage
LC-10 PAYLOAD METER DISPLAYS " :FULL"

(DATA SAVING MEMORY IS FULL)

Payload meter Payload meter displays " :FULL"
Trouble
Not set displays Not set (Data saving memory is full)
" :FULL"
Contents of trouble Payload meter displays " :FULL". (Data saving memory is full.)
Problem that
Payload meter displays " :FULL". (Data saving memory is full.)
appears on machine

Cycle data saving memory
Download the data to a personal computer and clear the memory to
1 full
"0" (zero ) according to the operation manual.
a"L. FULL" is displayed
Engine ON/OFF data saving
2 memory full
Possible causes "0" (zero ) according to the operation manual.
a"E. FULL" is displayed
and standard value
in normal state Failure and warning data
3 saving memory full
"0" (zero ) according to the operation manual.
a"F. FULL" is displayed
Integrated pay load and total
number of cycles data sav- Download the data to a personal computer and clear the memory to
4
ing memory full "0" (zero ) according to the operation manual.
a"F. FULL" is displayed
20-826 HD465-7, HD605-7

(10)
LC-11 PAYLOAD METER DISPLAYS "F-20"

: FAILURE IN POWER SOURCE OF SUSPENSION PRESSURE SENSOR AND
CLINOMETER SYSTEM
Action code Failure code Controller code LC-11 Payload meter displays "F-20"
Payload meter Trouble : Failure in power source of suspension pressure sensor and cli-
Not set Not set nometer system
displays "F-20"
Contents of trouble The sensor power source output is below 15 V while the source voltage is above 20 V.
Action of controller All the external pilot lamps flash.
Problem that Pay load is not displayed correctly.
appears on machine Operation data is not saved correctly.
Related information

2) Disconnect connectors PM6, SUFL, SUFR, SURL, SURR, and PM3.
Resistance between
Min. 1 M z
male) (2) SUFL (female) (B) SUFL (female) (B)
chassis ground
Resistance between
Min. 1 M z
male) (2) SUFR (female) (B) SUFR (female) (B)
chassis ground
ness
Min. 1 M z
male) (2) SURL (female) (B) SURL (female) (B)
chassis ground
Resistance between
Min. 1 M z
male) (2) SURR (female) (B) SURR (female) (B)
chassis ground
Resistance between
Possible causes
Wiring harness between PM6 (fe- PM6 (female) (2), PM3
and standard value Min. 1 M z
male) (2) PM3 (female) (C) (female) (C) chassis
in normal state
ground
2) Replace the sensor.
When front left suspension pressure sensor is Front left sensor is de-
replaced, the error is corrected. fective.
When front left suspension pressure sensor is Front left sensor is
replaced, the error is not corrected. normal.
When front right suspension pressure sensor Front right sensor is
is replaced, the error is corrected. defective.
Suspension pressure sensor
2 When front right suspension pressure sensor Front right sensor is
defective
is replaced, the error is not corrected. normal.
When rear left suspension pressure sensor is Rear left sensor is de-
When rear left suspension pressure sensor is Rear left sensor is nor-
replaced, the error is not corrected. mal.
When rear right suspension pressure sensor is Rear right sensor is
replaced, the error is corrected. defective.
When Rear right suspension pressure sensor Rear right sensor is
HD465-7, HD605-7 20-827

(10)

3 Clinometer sensor defective When the clinometer is replaced, the error is Clinometer is defec-
Possible causes corrected. tive.
and standard value When the clinometer is replaced, the error is
in normal state Clinometer is normal.
not corrected.
4 Payload meter defective 3) Connect T-adapter (only payload meter side).
Between PM6 (male) (2) (3) Voltage 18 3 V
20-828 HD465-7, HD605-7

(10)
LC-12 PAYLOAD METER DISPLAYS "F-21" "F-24"

: DISCONNECTION OR GROUNDING FAULT IN SUSPENSION SENSOR SIGNAL
SYSTEM
Payload meter displays "F-21" "F-24"
Payload meter Trouble : Disconnection or grounding fault in suspension sensor signal
Not set displays Not set system
"F-21" "F-24"
Contents of trouble Input signal of suspension pressure sensor is below 1 V.
Related information

2) Disconnect connectors PM6, SUFL, SUFR, SURL, and SURR.
Resistance Max. 1 z
SUFL (female) (B)
Resistance Max. 1 z
SUFR (female) (B)
Resistance Max. 1 z
SURL (female) (B)
Resistance Max. 1 z
SURR (female) (B)
Disconnection in wiring har- SUFL (female) (C) Resistance Max. 1 z
ness
1 Wiring harness between PM6 (female) (5)
SUFR (female) (C)
contact)
Resistance Max. 1 z
SURL (female) (C)
Resistance Max. 1 z
SURR (female) (C)
Resistance Max. 1 z
SUFL (female) (A)
Possible causes
in normal state SUFR (female) (A)
Resistance Max. 1 z
SURL (female) (A)
Resistance Max. 1 z
SURR (female) (A)
2) Disconnect connectors PM6, SUFL, SUFR, SURL, and SURR
Resistance between
Min. 1 M z
male) (4) SUFL (female) (C) SUFL (female) (C)
chassis ground
Resistance between
Ground fault in wiring har- Min. 1 M z
2 male) (5) SUFR (female) (C) SUFR (female) (C)
ness
chassis ground
Resistance between
Min. 1 M z
male) (6) SURL (female) (C) SURL (female) (C)
chassis ground
Resistance between
Min. 1 M z
male) (7) SURR (female) (C) SURR (female) (C)
chassis ground
HD465-7, HD605-7 20-829

(10)

defective
Possible causes When rear left suspension pressure sensor is Rear left sensor is nor-
and standard value replaced, the error is not corrected. mal.
in normal state
When Rear right suspension pressure sensor Rear right sensor is
2) Disconnect connectors PM5 and PM6.
4 Payload meter defective Between PM6 (2) (3) Voltage 18 3 V
Between PM6 (4) (3) Voltage 15V
20-830 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-831

(1)
LC-13 PAYLOAD METER DISPLAYS "F-25" "F-28"

: SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN SUSPENSION
SENSOR SIGNAL SYSTEM

Payload meter displays "F-25" "F-28"
Payload meter
Trouble : Short circuit with power source (Hot short) in suspension sensor
Not set displays Not set signal system
"F-25" "F-28"
Contents of trouble The suspension pressure input signal is above 5 V.
Related information

2) Disconnect connectors PM6, SUFL, SUFR, SURL, and SURR
Voltage between PM6
Wiring harness between PM6 (fe- (female) (4), SUFL (fe-
Max. 1 V
male) (4) SUFL (female) (C) male) (C) and chassis
ground
Voltage between PM6
Wiring harness between PM6 (fe- (female) (5), SUFR
male) (5) SUFR (female) (C) (female) (C) and chas-
sis ground
Voltage between PM6
Wiring harness between PM6 (fe- (female) (6), SURL (fe-
Max. 1 V
male) (6) SURL (female) (C) male) (C) and chassis
ground
Voltage between PM6
Wiring harness between PM6 (fe- (female) (7), SURR
Max. 1 V
Possible causes male) (7) SURR (female) (C) (female) (C) and chas-
and standard value sis ground
defective
20-832 HD465-7, HD605-7

(10)

and standard value
in normal state 3 Payload meter defective Between PM6 (2) (3) Voltage 18 3 V
HD465-7, HD605-7 20-833

(10)
LC-14 PAYLOAD METER DISPLAYS "F-CAL"

(NEGLIGENCE OF CALIBRATION OR INTERNAL DAMAGE OF PAYLOAD METER)

Payload meter Payload meter displays "F-CAL"
Trouble
Not set displays Not set (Negligence of calibration or internal damage of payload meter)
"F-CAL"
Contents of trouble Payload meter displays "F-CAL". (Negligence of calibration or internal damage of payload meter)
Problem that
Payload meter displays "F-CAL". (Negligence of calibration or internal damage of payload meter)
appears on machine

Possible causes Negligence of calibration or
and standard value internal damage of payload
in normal state 1 Repair according to the operation manual.
meter
a"F-CAL" is displayed.
20-834 HD465-7, HD605-7

(10)
LC-15 PAYLOAD METER DISPLAYS "F:43" "F:45"

(SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN EXTERNAL PILOT
LAMP RELAY SYSTEM)
Action code Failure code Controller code Payload meter displays "F:43" "F:45"
Trouble
Not set Not set Not set (Short circuit with power source in external pilot lamp relay system)
Contents of trouble There is short circuit with power source (Hot short) in external pilot lamp relay system.
Problem that There is short circuit with power source (Hot short) in external pilot lamp relay system.
appears on machine Payload meter displays "F:43" "F:45".

No
Payload meter lamp relays placed with normal ones respec- Relays (R43), (R44),
Yes
(R43), (R44), and (R45) de- tively, is failure repaired? and (R45) are defective
fective 1) Turn the starting switch OFF.
aWhen "F:43" is displayed, 2) Disconnect connectors R43, R44, and R45.
1 R43 is defective. 3) Check the relays.
aWhen "F:44" is displayed,
R44 is defective. Between R43, R44, and R45 (1) (2) Resistance 200 400 z
aWhen "F:45" is displayed, 1) Turn the starting switch OFF.
R45 is defective. 2) Disconnect connectors R43, R44, and R45.
Possible causes
Resistance Max. 1 z
in normal state Between R43, R44, (1) (2).
and R45 (3) (6). Do not apply 24 V be-
tween (1) (2).
2) Disconnect connectors PM5, R40, R43, R44, and R45.
Hot short in wiring harness Voltage between PM5
aWhen "F:43" is displayed, Wiring harness between PM5 (fe- (female) (4), R43 (fe-
R43 system is short-cir- Max. 1 V
cuited. ground
aWhen "F:44" is displayed,
2 Voltage between PM5
R44 system is short-cir-
cuited. Wiring harness between PM5 (fe- (female) (5), R44 (fe-
Max. 1 V
aWhen "F:45" is displayed, male) (5) R44 (female) (2) male) (2) chassis
R45 system is short-cir- ground
cuited. Voltage between PM5
Wiring harness between PM5 (fe- (female) (6), R45 (fe-
Max. 1 V
ground
HD465-7, HD605-7 20-835

(10)

2) Disconnect connectors R40, R43, R44, and R45.
Voltage between PM5
Max. 1 V
ground
3 Hot short in wiring harness Voltage between PM5
Max. 1 V
Possible causes ground
and standard value Voltage between PM5
in normal state Wiring harness between PM5 (fe- (female) (6), R45 (fe-
Max. 1 V
ground
Payload meter defective 1) Turn the starting switch OFF.
aWhen "F:43" is displayed, 2) Disconnect connector PM5.
PM5 (4) system is defec- 3) Insert T-adapter.
tive. 4) Connect the connector.
aWhen "F:44" is displayed, 5) Turn the starting switch ON.
4
PM5 (5) system is defec-
Between PM 5 (4) (13) Voltage 20 30 V
tive.
aWhen "F:45" is displayed, Between PM 5 (5) (13) Voltage 20 30 V
PM5 (6) system is defec-
tive. Between PM 5 (6) (13) Voltage 20 30 V
20-836 HD465-7, HD605-7

(10)
LC-16 PAYLOAD METER DISPLAYS "L-bad"

(CYCLE DATA WERE SAVED WHILE TRUCK BODY WAS PITCHING)
Action code Failure code Controller code Payload meter displays "L-bad"
Trouble
Not set Not set Not set (Cycle data were saved while truck body was pitching)
Contents of trouble Since truck pitches during dumping, the pay load in the cycle data is not correct.
Problem that
Since truck pitches during dumping, the pay load in the cycle data is not correct.
appears on machine
The pay load must be calculated accurately and saved as a cycle data when the truck dumps. If the
truck pitches when it dumps, the calculation accuracy is lowered. Pitching of the truck during dumping
is notified to the operator by "L-bad". Accordingly, wait for 5 seconds after the truck stops, and then
Related information start dumping.
If "L-bad" is displayed during dumping, it is maintained until the empty truck starts traveling.
If "L-bad" is always displayed and the pay load in the cycle data is abnormal, perform the following trou-
bleshooting.

2) Disconnect connectors PM5, PM6, SUFL, SUFR, SURL, and SURR.
Resistance Max. 1 z
SUFR (female) (A)
1 SUFL (female) (C)
SUFR (female) (C)
Resistance Max. 1 z
SURL (female) (C)
Resistance Max. 1 z
SURR (female) (C)
Possible causes 2) Replace the sensor.
and standard value 3) Turn the starting switch ON.
in normal state When front left suspension pressure sensor is Front left sensor is de-
defective
HD465-7, HD605-7 20-837

(10)

and standard value
in normal state 3 Payload meter defective Between PM6 (2) (3) Voltage 18 3 V
20-838 HD465-7, HD605-7

(10)
LC-17 EXTERNAL PILOT LAMP INDICATES FORECAST WHILE TRUCK IS NOT BEING
LOADED OR CLOCK IS DISPLAYED WHILE TRUCK TRAVELS FOR 160 M
AFTER IT IS LOADED
Action code Failure code Controller code External pilot lamp indicates forecast while truck is not being
Trouble loaded or clock is displayed while truck travels for 160 m after it
Not set Not set Not set is loaded
External pilot lamp indicates forecast while truck is not being loaded or clock is displayed while truck
Contents of trouble
travels for 160 m after it is loaded
Problem that External pilot lamp indicates forecast while truck is not being loaded or clock is displayed while truck
appears on machine travels for 160 m after it is loaded

and standard value
in normal state 1 Improper calibration Perform calibration according to the operation manual.
HD465-7, HD605-7 20-839

(10)

: GROUNDING FAULT OR DISCONNECTION IN CLINOMETER SENSOR SIGNAL
SYSTEM
Action code Failure code Controller code Payload meter displays "F-31"
Payload meter Trouble : Grounding fault or disconnection in clinometer sensor signal
Not set Not set system
displays "F-31"
Contents of trouble The signal circuit voltage of the clinometer sensor is below 1.6 V.
Before performing troubleshooting, check that the slope angle is 10 or less (if it exceeds 10, this phe-
Related information
nomenon does not indicate a failure) and the clinometer is installed normally.

1 PM3 (female) (B)
PM3 (female) (C)
Resistance Max. 1 z
PM3 (female) (A)
ness
Possible causes Wiring harness between PM6 (fe- PM6 (female) (8), PM3
Min. 1 M z
and standard value male) (8) PM3 (female) (B) (female) (B) chassis
in normal state ground
3 Clinometer sensor defective When the clinometer is replaced, error is cor- Clinometer is defec-
rected. tive.
When the clinometer is replaced, error is not
Clinometer is normal.
corrected.
Between PM6 (8) (3) Voltage 1.6 3.6 V
20-840 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-841

(1)

: SHORT CIRCUIT WITH POWER SOURCE IN CLINOMETER SENSOR SIGNAL
SYSTEM

Payload meter Trouble Payload meter displays "F-32"
Not set Not set
displays "F-32"
Contents of trouble The signal circuit voltage of the clinometer sensor is above 3.6 V.
Before performing troubleshooting, check that the slope angle is 10 or less (if it exceeds 10, this phe-
Related information
nomenon does not indicate a failure) and the clinometer is installed normally.

Voltage between PM6
Wiring harness between PM6 (fe- (female) (8), PM3 (fe-
Max. 1 V
male) (8) PM3 (female) (B) male) (B) chassis
ground
Possible causes 2) Disconnect connector PM3.
and standard value 3) Insert T-adapter.
in normal state 2 Clinometer sensor defective 4) Connect the connector.
Between PM3 (C) (A) Voltage 18 3 V
Between PM3 (B) (A) Voltage 1.6 3.6 V
3 Payload meter defective 4) Connect the connectors.
Between PM6 (2) PM5 (13) Voltage 18 3 V
Between PM6 (8) PM5 (13) Voltage 1.6 3.6 V
20-842 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-843

(1)
LC-20 PAYLOAD METER DISPLAYS "F:18"

(DISCONNECTION IN CHARGE LEVEL SIGNAL SYSTEM)
Action code Failure code Controller code Payload meter displays "F:18"
Trouble
Not set Not set Not set (Disconnection in charge level signal system)
Contents of trouble There is disconnection in the charge level signal system.
Problem that There is disconnection in the charge level signal system.
appears on machine Payload meter displays "F:18".
If failure code "AB00MA" (Malfunction of alternator) related to transmission controller is displayed, per-
Related information
form troubleshooting for it first.

1
(Disconnection or defective 5) Start the engine.
contact) 6) Depress the accelerator pedal more than "half".
Possible causes
Wiring harness between PM5 (fe- Voltage between PM5
and standard value Min. 5 V
male) (9) alternator terminal R (9) chassis ground
in normal state
6) Depress the accelerator pedal more than "half".
Between PM5 (9) chassis ground Voltage Min. 5 V
20-844 HD465-7, HD605-7

(10)
TROUBLESHOOTING FOR
MONITOR SYSTEM
(MON MODE)
Electrical system diagram related to monitor .............................................................................................. 20-904

Information in troubleshooting table........................................................................................................ 20-905
Phenomenon code table ......................................................................................................................... 20-906
[B@C7NS] Rear brake oil: overheating (NS) ........................................................................................ 20-907
[B@CENS] Torque converter: overheating (NS) ................................................................................... 20-907
[DAF0KM] Monitor panel: mistake in operation or setting (KM) ........................................................... 20-908
[DAF9KM] Monitor panel: mistake in operation or setting (KM) ........................................................... 20-911
[DAFSKQ] Monitor panel: disagreement of model selection signals (KQ) ........................................... 20-912
[DAQSKR] S-NET communication defective
(between transmission controller and machine monitor) (KR)............................................ 20-913
[DASRKR] CAN communication/Communication defective: abnormality in objective component (KR) .... 20-916
[DB1SKR] S-NET communication defective (between retarder controller and machine monitor) (KR)..... 20-918
[DV00KB] Short circuit in alarm buzzer output: short circuit (KB) ....................................................... 20-921
MON- 1 When starting switch is turned ON, machine monitor does not display any item ............... 20-922
MON- 2 When starting switch is turned OFF and machine monitor does not operate normally ...... 20-923
MON- 3 Alarm buzzer defective ....................................................................................................... 20-925
a) Alarm buzzer does not sound ....................................................................................... 20-925
b) Alarm buzzer does not stop sounding........................................................................... 20-926
MON- 4 Items displayed by gauges, warning lamps, and character display of machine monitor
are abnormal ...................................................................................................................... 20-927
a) Items displayed by gauges are different from machine condition ................................. 20-927
b) Items displayed by warning lamps are different from machine condition ...................... 20-928
c) Character display does not display any item or it displays abnormally ......................... 20-928
MON- 5 Operation of machine monitor cannot be checked normally .............................................. 20-929
MON- 6 Display of character display cannot be selected normally.................................................. 20-930
a) Machine monitor mode select switch 1 system is abnormal ......................................... 20-930
b) Machine monitor mode select switch 2 system is abnormal ......................................... 20-932
MON- 7 Power mode select function does not work normally ......................................................... 20-934
MON- 8 Seat belt warning lamp does not operate normally ............................................................ 20-935
a) Lamp lights up while seat belt is fastened..................................................................... 20-935
b) Lamp does not light up while seat belt is unfastened.................................................... 20-936
MON- 9 Turn signals and hazard lamp do not operate normally...................................................... 20-937
a) When turn signal lever and hazard lamp switch are operated, any turn signal lamp
does not flash................................................................................................................ 20-937
b) When turn signal lever and hazard lamp switch are operated, the turn signal lamps
do not flash but light up ................................................................................................. 20-938
c) When turn signal lever is operated, turn signal lamps on either or both sides do not flash
(When hazard lamp switch is operated, however, turn signal lamps flash normally) ......... 20-939
d) When hazard lamp switch is turned ON, any turn signal lamp does not flash
(When turn signal lever is operated, however, turn signal lamps flash normally).......... 20-940
e) When hazard lamp switch is turned OFF, turn signal lamps continue flashing
(When turn signal lever is operated, however, turn signal lamps flash normally).......... 20-942
f) Turn signal pilot lamps do not flash normally
(Turn signal lamps flash normally, however) ................................................................. 20-943
HD465-7, HD605-7 20-901

(10)
MON-10 Night lighting is abnormal ................................................................................................... 20-945
a) When lamp switch is set in 1st or 2nd position, any of small lamp, night lamp,
and head lamp does not light up. .................................................................................. 20-945
b) When lamp switch is set in 1st position, small lamp and night lamp do not light up ..... 20-946
c) When lamp switch is OFF, small lamp and night lamp light up ..................................... 20-947
d) When dimmer switch is operated, brightness of night lighting does not change........... 20-948
e) Head lamp "Hi" beam does not light up ........................................................................ 20-949
f) Head lamp "Lo" beam does not light up........................................................................ 20-950
g) Head lamp cannot be set to "Hi" or "Lo" ....................................................................... 20-951
h) When head lamp is set to "Hi" beam, pilot lamp of machine monitor does not light up ... 20-952
MON-11 Power window does not operate normally.......................................................................... 20-954
a) Operating left side does not .......................................................................................... 20-954
b) Operating right side does not ........................................................................................ 20-955
MON-12 Defective air conditioner ..................................................................................................... 20-957
a) Air conditioner does not operate ................................................................................... 20-957
b) Air does not come out or air flow cannot be adjusted ................................................... 20-958
c) Air is not cooled or temperature cannot be adjusted (Electric system) ......................... 20-960
d) Recirculated air and fresh air cannot be selected ......................................................... 20-962
e) Air outlets cannot be selected ....................................................................................... 20-963
f) Air is not cooled (Mechanical system)........................................................................... 20-965
g) Air is not heated (Defective hot water circuit)................................................................ 20-966
h) Abnormal sound comes out .......................................................................................... 20-966
i) Water leaks ................................................................................................................... 20-967
a For abnormality of the fuel level gauge, see troubleshooting for the transmission controller system (TM
Mode).
20-902 HD465-7, HD605-7

(5)
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED TO MONITOR
ELECTRICAL SYSTEM DIAGRAM RELATED TO MONITOR

20-904 HD465-7, HD605-7

(2)

panel panel panel
Problem that
appears on machine

Remarks on judgment
1
Disconnection
Ground fault
Short circuit
indicate priority)
side.
side.
5
side.
HD465-7, HD605-7 20-905

(10)


code code

input

sistency
source (Hot short)
cuit
MW Sliding
NS Overheat
20-906 HD465-7, HD605-7

(10)
TROUBLESHOOTING [B@C7NS], [B@CENS]
[B@C7NS] REAR BRAKE OIL: OVERHEATING (NS)
Action code Failure code Controller code Rear brake oil: Overheating (NS)
Trouble
E02 B@C7NS MON (Brake cooling oil overheating)
Contents of trouble Brake cooling oil is overheating.
Problem that
If the machine is used without repairing, the rear brake may be broken.
appears on machine
Related information This failure code is displayed when possibility of occurrence of a failure in the electric system is low.

Possible causes Overheating of brake cool-
1
and standard value ing oil
in normal state
If the brake cooling oil is not overheating, the machine monitor is de-
fective.
[B@CENS] TORQUE CONVERTER: OVERHEATING (NS)

Trouble Torque converter: Overheating (NS)
E02 B@CENS MON
Contents of trouble Torque converter is overheating
Problem that
If the machine is used without repairing, the torque may be broken.
appears on machine
Related information This failure code is displayed when possibility of occurrence of a failure in the electric system is low.

Possible causes Overheating of torque con-
1
and standard value verter
in normal state
If the torque converter is not overheating, the machine monitor is de-
fective.
HD465-7, HD605-7 20-907

(10)
TROUBLESHOOTING [DAF0KM]
[DAF0KM] MONITOR PANEL: MISTAKE IN OPERATION OR SETTING (KM)

Action code Failure code Controller code Monitor panel: Mistake in operation or setting (KM)
Trouble
E03 DAF0KM MON (Disagreement of optional settings)
The optional settings of the rotary switch and dip switch on the rear side of the machine monitor do not
Contents of trouble
agree with the signals of the optional setting connector.
The controller maintains the abnormal state until the starting switch is turned OFF.
The controller does not recognize the functions (If equipped), the settings of which do not agree the
signals.
The controller does not record this failure in the fault history.
Problem that
Some functions (If equipped) do not work.
appears on machine
Connections of wiring harnesses OP1OP7 depend on the specification. For details, see "Adjustment
of machine monitor".
This failure can be checked with SW13 (monitor code: 30800), SW51, 52 (monitor code: 30900),
Related information SW53, 54 (monitor code: 30901), SW61, 62 (monitor code: 30902), SW63, and 64 (monitor
code: 30903) on the rear side of the machine monitor.
This failure can be checked with optional selection connectors OP1, 2 (monitor code: 31000), OP3, 4
(monitor code: 31001), and OP5, 6 (monitor code: 31002).

2) Disconnect connector DPC3A.
Resistance between
When connected
Wiring harness (CLOSED) DPC3A (female) (4) Max. 1 z
between DPC3A chassis ground
(female) (4) When discon- Resistance between
OP1 (female) (1) nected DPC3A (female) (4) Min. 1 M z
(OPENED) chassis ground
Resistance between
When connected
Possible causes
and standard value Resistance between
Ground fault in wiring har- When connected
in normal state 1 Wiring harness (CLOSED) DPC3A (female) (7) Max. 1 z
ness
Resistance between
When connected
OP4 (female) (1) nected DPC3A (female) ((13) Min. 1 M z
Resistance between
When connected
20-908 HD465-7, HD605-7

(10)

Resistance between
When connected
Ground fault in wiring har- (OPENED) chassis ground
1
When connected
When connected
Resistance between (CLOSED) Resistance Max. 1 z
DPC3A (female) (4)
When disconnected
chassis ground Resistance Min. 1 M z
(OPENED)
When connected
Possible causes Resistance between (CLOSED) Resistance Max. 1 z
and standard value DPC3A (female) (6)
When disconnected
in normal state chassis ground Resistance Min. 1 M z
(OPENED)
When connected
DPC3A (female) (7)
When disconnected
(OPENED)
2 Machine monitor defective When connected
DPC3A (female) (13)
When disconnected
(OPENED)
When connected
DPC3A (female) (14)
When disconnected
(OPENED)
When connected
DPC3A (female) (15)
When disconnected
(OPENED)
When connected
DPC3A (female) (16)
When disconnected
(OPENED)
HD465-7, HD605-7 20-909

(10)
20-910 HD465-7, HD605-7

(1)
[DAF9KM] MONITOR PANEL: MISTAKE IN OPERATION OR SETTING (KM)
Action code Failure code Controller code Monitor panel: Mistake in operation or setting (KM)
Trouble
E03 DAF9KM MON (Wrong connection of connector)
Contents of trouble The check signal of the connector does not agree with the internal setting of the machine monitor.
The controller does not record this failure in the fault history.
The machine monitor mode select switch does not work.
Problem that
The optional functions do not work.
appears on machine
The head lamp HIGH pilot lamp, turn signal pilot lamp, output mode pilot lamp, etc. do not work.

The connector check signal connectors are connected normally.
1 aConnector check signal connectors: DPC3A (5) (OPEN), DPC2A (5)
nector
(CLOSE)
Disconnection in wiring har- 2) Disconnect connector DPC2A.
2
Wiring harness between fuse terminal BT4 (2)
DPC2A (female) (5)
and standard value 2) Disconnect connector DPC3A.
3 ness Wiring harness between DPC3A (female) (5)
(Grounding fault of terminal) chassis ground
aThis must not occur basically, since the wiring harness is not con-
nected.
4 Machine monitor defective 3) Connect T-adapter.
Resistance between DPC2A (female) (5)
chassis ground
HD465-7, HD605-7 20-911

(10)
TROUBLESHOOTING [DAFSKQ]
[DAFSKQ] MONITOR PANEL: DISAGREEMENT OF MODEL SELECTION SIGNALS (KQ)

Trouble Monitor panel: Disagreement of model selection signals (KQ)
E03 DAFSKQ MON
Since communication with the transmission controller (S-NET) is defective, model selection informa-
Contents of trouble
tion cannot be received or the rotary switch of the transmission controller is not set normally.
The controller controls the truck as HD465-7.
Problem that None of the meters and gauges display.
appears on machine Some panel switches and lamps do not work.
Related information If another failure code "DAQAKQ" is displayed, perform troubleshooting for it.

Communication circuit de-
1 Perform troubleshooting for "DAQSKR".
fective
Possible causes aIf the failure is not repaired by replacing the machine monitor, the
and standard value machine monitor is defective.
in normal state aWhen replacing the machine monitor, see TESTING AND ADJUST-
ING, Adjustment of machine monitor.
Transmission controller de- aIf the failure is not repaired by replacing the machine monitor, the
3
fective transmission controller is defective.
20-912 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DAQSKR]
[DAQSKR] S-NET COMMUNICATION DEFECTIVE (BETWEEN TRANSMISSION CON-

TROLLER AND MACHINE MONITOR) (KR)
Action code Failure code Controller code S-NET communication defective (KR)
Trouble
E03 DAQSKR MON (Between transmission controller and machine monitor)
Contents of trouble Communication (S-NET) information cannot be obtained from the transmission controller.
Action of controller The controller maintains the condition at the time when the failure occurs.
Problem that The meters, gauges, warning lamps, and special functions that obtain information from the transmis-
appears on machine sion controller do not operate or display.
Related information

2) Disconnect connectors JCB, JCC, JCD, JCE, JCF, and JCG.
Between each couple of JCB (male) terminals Resistance Max. 1 z
1 Junction connector defective Between each couple of JCC (male) terminals Resistance Max. 1 z
Between each couple of JCD (male) terminals Resistance Max. 1 z
Between each couple of JCE (male) terminals Resistance Max. 1 z
Between each couple of JCF (male) terminals Resistance Max. 1 z
Between each couple of JCG (male) terminals Resistance Max. 1 z
2) Disconnect connectors DPC4, ATC4, and BRC4.
Wiring harness between DPC4 (female) (1)
Resistance Max. 1 z
ATC4 (female) (12)
Disconnection in wiring har- ATC4 (female) (6) Resistance Max. 1 z
ness
2
(Disconnection or defective Wiring harness between DPC4 (female) (4) Resistance Max. 1 z
contact) ATC4 (female) (10)
ATC4 (female) (10)
and standard value
in normal state aIf another controller also has an error in S-NET communication, per-
form troubleshooting from the wiring harness.
aDisconnect the connectors to which the S-NET signals of all the con-
trollers connected to S-NET are allotted.
Between DPC4 (female) (1), (2) chassis
Ground fault in wiring har- Resistance Min. 1 M z
3 ground
ness
aIf another controller also has an error in S-NET communication, per-
4 Hot short in wiring harness Voltage Max. 1 V
ground
HD465-7, HD605-7 20-913

(10)

and standard value Transmission controller de- Between ATC4 (6) (10) Voltage 69V
in normal state 5
fective Between ATC4 (12) (10) Voltage 69V
aIf any other controller does not have an error in S-NET communica-
tion, disconnect only the S-NET signal output of the transmission
controller and check that the transmission controller is outputting the
normal voltage.
20-914 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-915

(2)
TROUBLESHOOTING [DASRKR]
[DASRKR] CAN COMMUNICATION/COMMUNICATION DEFECTIVE: ABNORMALITY IN

OBJECTIVE COMPONENT (KR)
Action code Failure code Controller code CAN communication/Communication defective: Abnormality in
Trouble objective component (KR)
E03 DASRKR MON (Between engine controller and machine monitor)
Contents of trouble Communication (CAN) information cannot be obtained from the engine controller.
Problem that The meters, gauges, warning lamps, and special functions that obtain information from the engine con-
appears on machine troller do not operate or display.
Related information

2) Disconnect connector JC14.
1 Junction connector defective 3) Connect T-adapter.
Between JC14 (male) (2) (8) Resistance Max. 1 z
Between JC14 (male) (4) (6) Resistance Max. 1 z
2) Disconnect connectors DPC4 and ECMB.
Resistance 40 80 z
DPC4 (female) (8)
2 Wiring harness defective
aCheck that terminal resistors CAN and CAN2 are connected. The
resistance of each terminal resistor is 120 z.
aCheck that a personal computer or a controller is not connected to
CAN1.
Possible causes aIf VHMS is connected, disconnect it.
and standard value
2) Replace the engine controller.
3 Engine controller defective Engine controller is
When the engine controller is re- No
normal.
placed, does communication be-
come normal? Engine controller is
Yes
defective.
2) Replace the machine monitor.
Machine monitor is
When the machine monitor is re- No
4 Machine monitor defective normal.
placed, does communication be-
come normal? Machine monitor is de-
Yes
fective
aWhen replacing the machine monitor, see TESTING AND ADJUST-
ING, Adjustment of machine monitor.
20-916 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DASRKR]
HD465-7, HD605-7 20-917

(1)
TROUBLESHOOTING [DB1SKR]
[DB1SKR] S-NET COMMUNICATION DEFECTIVE (BETWEEN RETARDER CONTROL-

LER AND MACHINE MONITOR) (KR)
Action code Failure code Controller code S-NET communication defective (KR)
Trouble
E03 DB1SKR MON (Between retarder controller and machine monitor)
Contents of trouble Communication (S-NET) information cannot be obtained from the retarder controller.
Problem that The meters, gauges, warning lamps, and special functions that obtain information from the retarder
appears on machine controller do not operate or display.
Related information

2) Disconnect connectors JCB, JCC, JCD, JCE, JCF, and JCG.
Between each couple of JCB (male) terminals Resistance Max. 1 z
1 Junction connector defective Between each couple of JCC (male) terminals Resistance Max. 1 z
Between each couple of JCD (male) terminals Resistance Max. 1 z
Between each couple of JCE (male) terminals Resistance Max. 1 z
Between each couple of JCF (male) terminals Resistance Max. 1 z
Between each couple of JCG (male) terminals Resistance Max. 1 z
Resistance Max. 1 z
BRC4 (female) (12)
Disconnection in wiring har- BRC4 (female) (6) Resistance Max. 1 z
ness
2
(Disconnection or defective Wiring harness between DPC4 (female) (4) Resistance Max. 1 z
contact) BRC4 (female) (10)
BRC4 (female) (10)
and standard value
in normal state aIf another controller also has an error in S-NET communication, per-
Ground fault in wiring har- Resistance Min. 1 M z
3 ground
ness
4 Hot short in wiring harness Voltage Max. 1 V
ground
20-918 HD465-7, HD605-7

(10)

and standard value
in normal state 5 Retarder controller defective Between BRC4 (6) (10) Voltage 69V
Between BRC4 (12) (10) Voltage 69V
aIf any other controller does not have an error in S-NET communica-
tion, disconnect only the S-NET signal output of the retarder control-
ler and check that the retarder controller is outputting the normal
voltage.
HD465-7, HD605-7 20-919

(10)
20-920 HD465-7, HD605-7

(2)
TROUBLESHOOTING [DV00KB]
[DV00KB] SHORT CIRCUIT IN ALARM BUZZER OUTPUT: SHORT CIRCUIT (KB)

Trouble Short circuit in alarm buzzer output: Short circuit (KB)
E01 DV00KB MON
Contents of trouble There is short circuit with the power source in the output circuit of the alarm buzzer.
The controller turns the output circuit of the alarm buzzer OFF.
Problem that
The alarm buzzer does not sound.
appears on machine

2) Disconnect connectors DPC1 and BZ2.
Voltage between
Wiring harness between DPC1 DPC1 (female) (13),
Max. 1 V
(female) (13) BZ2 (female) (2) BZ2 (female) (2)
Possible causes
chassis ground
and standard value
2) Disconnect connector BZ2 (2) and remove the buzzer.
3) Connect +24 V to BZ2 (male) (1) and connect GND to BZ2 (male) (2).
2 Alarm buzzer defective The alarm buzzer sounds. Alarm buzzer is normal.
The alarm buzzer does not sound. Alarm buzzer is defective.
aCheck the alarm buzzer unit.
If the results of 1) and 2) above are normal, the machine monitor is
defective.
HD465-7, HD605-7 20-921

(10)
TROUBLESHOOTING MON-1
MON-1 WHEN STARTING SWITCH IS TURNED ON, MACHINE MONITOR DOES NOT
DISPLAY ANY ITEM
Action code Failure code Controller code When starting switch is turned ON, machine monitor does not
Trouble
Not set Not set MON display any item
Contents of trouble When the starting switch is turned ON, machine monitor does not display any of the lamps and gauges.
Problem that
When the starting switch is turned ON, machine monitor does not display any of the lamps and gauges.
appears on machine
Related information Before performing troubleshooting, check that fuses BT2 (2) and BT2 (22) and fusible link FUA are not
broken.

Disconnection in wiring har- Wiring harness between battery Voltage between BT2
20 30 V
ness relay B fuse BT2 (1) (1) and chassis ground
1
(Disconnection or defective Voltage between
contact) Wiring harness between fuse BT2
DPC1 (6), (7) and 20 30 V
(2) DPC1 (female) (6), (7)
chassis ground
and standard value 2) Disconnect connectors DPC4 and BRC4.
Wiring harness between DPC1 (9), (10)
Resistance Max. 1 z
chassis ground
Between DPC1(6), (7) (9), (10) Voltage 20 30 V
20-922 HD465-7, HD605-7

(10)
MON-2 WHEN STARTING SWITCH IS TURNED OFF AND MACHINE MONITOR DOES
NOT OPERATE NORMALLY
Action code Failure code Controller code When starting switch is turned OFF and machine monitor does
Trouble
Not set Not set MON not operate normally
When the starting switch is turned OFF and the machine monitor mode select switch is operated, the
service meter and odometer are not displayed.
Contents of trouble
When the starting switch is turned OFF and the hazard lamp switch is operated, the hazard lamp is not
turned on.
When the starting switch is turned OFF and the machine monitor mode select switch is operated, the
Problem that service meter and odometer are not displayed.
appears on machine When the starting switch is turned OFF and the hazard lamp switch is operated, the hazard lamp is not
turned on.
Before performing troubleshooting, check that fuses BT2 (2) and BT2 (22) and fusible link FUA are not
Related information
broken. (If any of them is broken, there is a grounding fault. Accordingly, check the related wiring har-
ness.)

When the starting switch is turned
Main power source (SW power
ON, the machine monitor operates
source) is normal.
normally.
Main power source (SW Even if the starting switch is turned
1 Main power source (SW power
power source) defective ON, the machine monitor does not
source) is defective.
operate normally.
aIf the main power source (SW power source) is defective, perform
troubleshooting of MON-1.
Disconnection in wiring har- Wiring harness between J01 (fe- Voltage between BT2
20 30 V
ness male) (Y) fuse BT2 (21) (21) chassis ground
Possible causes 2
(Disconnection or defective Voltage between
and standard value Wiring harness between fuse BT2
contact) DPC1 (4), (5) chas- 20 30 V
in normal state (22) DPC1 (female) (4), (5)
sis ground
Hazard lamp switch, related
3 wiring harness, or related re- aReferring to MON-9 d), perform troubleshooting.
lay defective
Machine monitor mode se-
4 lect switch 1 or related wiring aReferring to MON-6, perform troubleshooting.
harness defective
5 Machine monitor defective 3) Insert T-adapter.
aKeep the starting switch OFF.
Between DPC1 (4), (5) (9), (10) Voltage 20 30 V
HD465-7, HD605-7 20-923

(10)
20-924 HD465-7, HD605-7

(1)
MON-3 ALARM BUZZER DEFECTIVE

a) Alarm buzzer does not sound
Action code Failure code Controller code Alarm buzzer defective

Trouble
Not set Not set MON a) Alarm buzzer does not sound
When the starting switch is ON or an emergency stop item lights up or the centralized warning lamps
Contents of trouble
light up, the alarm buzzer does not sound.
Problem that When the starting switch is ON or an emergency stop item lights up or the centralized warning lamps
appears on machine light up, the alarm buzzer does not sound.
If failure code "DV00KB" is displayed, perform troubleshooting for it.
Related information
Before performing troubleshooting, check that the fuse is not broken and the voltage between BZ2 and
chassis ground is 20 30 V when the starting switch is ON.

2) Disconnect connectors BZ2 and battery BT4 terminal (2).
ness
1 Wiring harness between fuse BT4 (2) BZ2
(female) (1)
contact)
Wiring harness between BZ2 (female) (2)
Resistance Max. 1 z
DPC (female) (13)
2) Connect BZ2 (2) to the chassis ground.
2 Alarm buzzer defective
Possible causes The alarm buzzer sounds. Alarm buzzer is normal.
and standard value The alarm buzzer does not sound. Alarm buzzer is defective.
in normal state
Under the condition for turning the Voltage between
Max. 1 V
3 Machine monitor defective alarm buzzer ON DPC1 (13) (9), (10)
20 30 V
alarm buzzer OFF DPC1 (13) (9), (10)
aThe condition for turning the alarm buzzer ON is that the starting
switch is ON, an emergency stop item lights up, the centralized
warning lamps light up, etc.
HD465-7, HD605-7 20-925

(10)
b) Alarm buzzer does not stop sounding
Action code Failure code Controller code Alarm buzzer defective

Trouble
Not set Not set MON b) Alarm buzzer does not stop sounding
When the starting switch is ON or an emergency stop item lights up or the centralized warning lamps
Contents of trouble
light up, the alarm buzzer does not sound.
Problem that When the starting switch is ON or an emergency stop item lights up or the centralized warning lamps
appears on machine light up, the alarm buzzer does not sound.
Related information
If failure code "DV00KB" is displayed, perform troubleshooting for it.

2) Disconnect connectors BZ2 and battery BT4 terminal (2).
Short circuit in wiring har- Resistance between wiring harness between fuse BT4 (2)
1
ness BZ2 (female) (1) and wiring harness between DPC1 (fe- Min. 1 M z
male) (13) BZ2 (female) (2)
Wiring harness between BZ2 (female) (2)
Resistance Max. 1 z
DPC (female) (13)
Possible causes
in normal state 2) Disconnect connector DPC1.
Max. 1 V
2 Machine monitor defective alarm buzzer ON DPC1 (13) (9), (10)
20 30 V
alarm buzzer OFF DPC1 (13) (9), (10)
aThe condition for turning the alarm buzzer ON is that the starting
switch is ON, an emergency stop item lights up, the centralized
warning lamps light up, etc.
20-926 HD465-7, HD605-7

(10)
MON-4 ITEMS DISPLAYED BY GAUGES, WARNING LAMPS, AND CHARACTER DIS-

PLAY OF MACHINE MONITOR ARE ABNORMAL
a) Items displayed by gauges are different from machine condition
Action code Failure code Controller code Items displayed by gauges, warning lamps, and character dis-
Trouble play of machine monitor are abnormal
Not set Not set MON a) Items displayed by gauges are different from machine condition
The items displayed by the gauges, warning lamps, and character display of the machine monitor are
Contents of trouble
abnormal. (The items displayed by the gauges are different from the machine condition.)
Problem that The items displayed by the gauges, warning lamps, and character display of the machine monitor are
appears on machine abnormal. (The items displayed by the gauges are different from the machine condition.)

2) Operate the machine monitor.
If the inputting condition of the related sensor
Sensor signal system
signal is monitored, the gauges display nor-
is normal.
Sensor signal system defec- mally.
1
tive If the inputting condition of the related sensor
Possible causes Sensor signal system
signal is monitored, the gauges do not display
and standard value is defective.
normally.
in normal state
aIf the sensor signal system is defective, perform troubleshooting for
each related signal system.
If the machine monitor check switch is operat- Machine monitor is
2 Machine monitor defective ed, the gauges display normally. normal.
If the machine monitor check switch is operat- Machine monitor is de-
ed, the gauges do not display normally. fective.
HD465-7, HD605-7 20-927

(10)
b) Items displayed by warning lamps are different from machine condition
Action code Failure code Controller code Items displayed by gauges, warning lamps, and character display
of machine monitor are abnormal
Trouble
Not set Not set MON b) Items displayed by warning lamps are different from machine
condition
Contents of trouble
abnormal. (The items displayed by the warning lamps are different from the machine condition.)
appears on machine abnormal. (The items displayed by the warning lamps are different from the machine condition.)

2) Operate the machine monitor.
If the inputting condition of the related sensor
Switch or sensor sig-
signal is monitored, the gauges display nor-
nal system is normal.
mally.
Switch or sensor signal sys- If the inputting condition of the related sensor Switch or sensor sig-
1
tem defective signal is monitored, the gauges do not display nal system is defec-
Possible causes normally. tive.
and standard value
in normal state aIf the switch or sensor signal system is defective, perform trouble-
shooting for each related signal system.
(See troubleshooting for the controllers to which the related sensor
signals are input.)
If the machine monitor check switch is operat- Machine monitor is
2 Machine monitor defective ed, the lamps display normally. normal.
If the machine monitor check switch is operat- Machine monitor is de-
ed, the lamps do not display normally. fective.
c) Character display does not display any item or it displays abnormally
Action code Failure code Controller code Items displayed by gauges, warning lamps, and character display
of machine monitor are abnormal
Trouble
Not set Not set MON c) Character display does not display any item or it displays abnor-
mally
Contents of trouble
abnormal. (The character display does not display any item or it displays abnormally.)
appears on machine abnormal. (The character display does not display any item or it displays abnormally.)

Possible causes If the machine monitor check switch is operat- Machine monitor is
and standard value ed, the character display displays normally. normal.
in normal state 1 Machine monitor defective
If the machine monitor check switch is operat-
Machine monitor is de-
ed, the character display does not display nor-
fective.
mally.
20-928 HD465-7, HD605-7

(10)
MON-5 OPERATION OF MACHINE MONITOR CANNOT BE CHECKED NORMALLY

Trouble Operation of machine monitor cannot be checked normally
Not set Not set MON
When the machine monitor check switch is operated, any of the lamps and gauges does not display.
Contents of trouble
Or, the lamps continue the operation while the machine monitor check switch is not operated.
Problem that When the machine monitor check switch is operated, any of the lamps and gauges does not display.
appears on machine Or, the lamps continue the operation while the machine monitor check switch is not operated.

2) Disconnect connector CK1.
3) Check the switch
Machine monitor check
1 Between Operate (Press) the machine mon-
switch defective Resistance Max. 1 z
CK1 itor check switch.
(male) (3) Do not operate (Release) the ma-
(6) Resistance Min. 1 M z
chine monitor check switch.
2) Disconnect connectors DPC2A, CK1, and fuse BT2 terminal (2).
2 Wiring harness between fuse BT2 (2) CK1
and standard value (Disconnection or defective Resistance Max. 1 z
(female) (3)
in normal state contact)
Wiring harness between DPC2A (female) (10)
Resistance Max. 1 z
CK1 (female) (6)
Between Operate (Press) the machine mon-
Voltage 20 30 V
DPC2A itor check switch.
(10)
chassis Do not operate (Release) the ma-
Voltage Max. 1 V
ground chine monitor check switch.
HD465-7, HD605-7 20-929

(10)
MON-6 DISPLAY OF CHARACTER DISPLAY CANNOT BE SELECTED NORMALLY

a) Machine monitor mode select switch 1 system is abnormal
Action code Failure code Controller code Display of character display cannot be selected normally
Trouble
Not set Not set MON a) Machine monitor mode select switch 1 system is abnormal
Display of the character display cannot be selected normally. (Machine monitor mode select switch 1
Contents of trouble
system is abnormal.)
Problem that Display of the character display cannot be selected normally. (Machine monitor mode select switch 1
appears on machine system is abnormal.)

2) Disconnect connector CH1.
Between Press [ ] of the machine monitor
Resistance Max. 1 z
Machine monitor mode se- CH1 select switch 1.
1 lect switch 1 system defec- (male) (2) Set the machine monitor select
tive switch in NEUTRAL.
Between Set the machine monitor select
CH1 switch in NEUTRAL.
(male) (1) Press [ ] of the machine monitor
(3) Resistance Max. 1 z
select switch 1.
2) Disconnect connectors DPC2A, CH1, and fuse BT2 terminal (22).
Disconnection in wiring har- Wiring harness between fuse BT2 (22) CH1
2 (female) (3)
CH1 (female) (2)
Resistance Max. 1 z
CH1 (female) (1)
and standard value 2) Disconnect connectors DPC2A and CH1.
Voltage between
Wiring harness between DPC2A DPC2A (female) (8),
Max. 1 V
3 Hot short in wiring harness (female) (8) CH1 (female) (2) CH1 (female) (2)
chassis ground
Voltage between
Max. 1 V
(female) (14) CH1 (female) (1) CH1 (female) (1)
chassis ground
Between Press [ ] of the machine monitor
Voltage 20 30 V
DPC2A select switch 1.
(8) chas- Set the machine monitor select
sis ground Voltage Max. 1 V
switch in NEUTRAL.
Voltage Max. 1 V
DPC2A switch in NEUTRAL.
(14)
chassis Press [ ] of the machine monitor
Voltage 20 30 V
ground select switch 1.
20-930 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-931

(1)
b) Machine monitor mode select switch 2 system is abnormal
Action code Failure code Controller code Display of character display cannot be selected normally
Trouble
Not set Not set MON a) Machine monitor mode select switch 2 system is abnormal
Display of the character display cannot be selected normally. (Machine monitor mode select switch 2
Contents of trouble
system is abnormal.)
Problem that Display of the character display cannot be selected normally. (Machine monitor mode select switch 2
appears on machine system is abnormal.)

2) Disconnect connector CH2.
Between Press [>] of the machine monitor
Resistance Max. 1 z
Machine monitor mode se- CH2 select switch 2.
1 lect switch 2 system defec- (male) (2) Set the machine monitor select
tive switch in NEUTRAL.
Between Set the machine monitor select Resistance Min. 1 M z
CH2 switch in NEUTRAL.
(male) (1) Press [<] of the machine monitor
(3) Resistance Max. 1 z
select switch 2.
2) Disconnect connectors DPC2A, CH2, and fuse BT2 terminal (2).
Disconnection in wiring har- Wiring harness between fuse BT2 (2) CH2
2 (female) (3)
CH2 (female) (2)
Resistance Max. 1 z
CH2 (female) (1)
and standard value 2) Disconnect connectors DPC2A and CH2.
Voltage between
Max. 1 V
3 Hot short in wiring harness (female) (6) CH2 (female) (2) CH2 (female) (2)
chassis ground
Voltage between
Max. 1 V
(female) (15) CH2 (female) (1) CH2 (female) (1)
chassis ground
Between Press [>] of the machine monitor
Voltage 20 30 V
DPC2A select switch 2.
(6) chas- Set the machine monitor select
sis ground Voltage Max. 1 V
switch in NEUTRAL.
Voltage Max. 1 V
DPC2A switch in NEUTRAL.
(15)
chassis Press [<] of the machine monitor
Voltage 20 30 V
ground select switch 2.
20-932 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-933

(1)
MON-7 POWER MODE SELECT FUNCTION DOES NOT WORK NORMALLY

Trouble Power mode select function does not work normally
Not set Not set MON
When the power mode select switch is operated, the power mode select function does not work nor-
Contents of trouble
mally.
Problem that When the power mode select switch is operated, the power mode select function does not work nor-
appears on machine mally.

2) Disconnect connector PWM.
Set the power mode select switch
Power mode select switch
1 Between in ECONOMY MODE (Press its Resistance Min. 1 M z
defective
PWM upper part).
(male) (1) Set the power mode select switch
(3) in HIGH POWER MODE (Press its Resistance Max. 1 z
lower part: Normal work).
2) Disconnect connectors DPC2A, PWM, and fuse BT2 terminal (2).
and standard value 2 (Disconnection or defective Wiring harness between fuse BT2 (2) PWM Resistance Max. 1 z
in normal state (female) (1)
contact)
Resistance Max. 1 z
PWM (female) (3)
3 Machine monitor defective Set the power mode select switch
Between in ECONOMY MODE (Press its Voltage 20 30 V
DPC2A upper part).
(13)
chassis Set the power mode select switch
ground in HIGH POWER MODE (Press its Voltage Max. 1 V
lower part: Normal work).
20-934 HD465-7, HD605-7

(10)
MON-8 SEAT BELT WARNING LAMP DOES NOT OPERATE NORMALLY

a) Lamp lights up while seat belt is fastened
Action code Failure code Controller code Seat belt warning lamp does not operate normally
Trouble
Not set Not set Not set a) Lamp lights up while seat belt is fastened
Contents of trouble The lamp lights up while the seat belt is fastened.
Problem that
The lamp lights up while the seat belt is fastened.
appears on machine

2) Disconnect connector SBS.
1 Seat belt switch defective 3) Check the switch.
Between SBS (male) Seat belt "Fastened" Resistance Max. 1 z
(1) (2) Seat belt "Unfastened" Resistance Min. 1 M z
2) Disconnect connectors DPC2B, SBS, and fuse BT2 terminal (2).
and standard value 2 (Disconnection or defective Wiring harness between fuse BT2 (2) SBS Resistance Max. 1 z
in normal state (female) (1)
contact)
Resistance Max. 1 z
SBS (female) (2)
2) Disconnect connector DPC2B.
3 Machine monitor defective 4) Connect the connector.
Between DPC2B (11) Seat belt "Fastened" Voltage 20 30 V
chassis ground Seat belt "Unfastened" Voltage Max. 1 V
HD465-7, HD605-7 20-935

(10)
b) Lamp does not light up while seat belt is unfastened
Action code Failure code Controller code Seat belt warning lamp does not operate normally
Trouble
Not set Not set MON b) Lamp does not light up while seat belt is unfastened
Contents of trouble The lamp does not light up while the seat belt is unfastened.
Problem that
The lamp does not light up while the seat belt is unfastened.
appears on machine

2) Disconnect connector SBS.
1 Seat belt switch defective 3) Check the switch.
Between SBS (male) Seat belt "Fastened" Resistance Max. 1 z
(1) (2) Seat belt "Unfastened" Resistance Min. 1 M z
2) Disconnect connectors DPC2B, SBS, and fuse BT2 terminal (2).
and standard value 2 ness Voltage between
contact) Wiring harness between DPC2B DPC2B (female) (11),
Max. 1 V
(female) (11) SBS (female) (2) SBS (female) (2)
chassis ground
Between DPC2B (11) Seat belt "Fastened" Voltage 20 30 V
chassis ground Seat belt "Unfastened" Voltage Max. 1 V
20-936 HD465-7, HD605-7

(10)
MON-9 TURN SIGNALS AND HAZARD LAMP DO NOT OPERATE NORMALLY

a) When turn signal lever and hazard lamp switch are operated, any turn signal lamp does not flash
Action code Failure code Controller code Turn signals and hazard lamp do not operate normally
Trouble a) When turn signal lever and hazard lamp switch are operated,
Not set Not set Not set any turn signal lamp does not flash
Contents of trouble When the turn signal lever and hazard lamp switch are operated, any turn signal lamp does not flash
Problem that
When the turn signal lever and hazard lamp switch are operated, any turn signal lamp does not flash
appears on machine
Before performing troubleshooting, check that fuse BT2 (24) and BT3 (4) are not broken. (If either or
both of them are broken, there is a grounding fault. Accordingly, check the related wiring harness.)
The turn signal lamps are branched at the switch and relay to the front, rear, right, and left. Accordingly,
Related information if only 1 lamp is defective, the possible causes of the failure are breakage of the bulb, defect of the
wiring harness on the signal side (between the branching point and lamp), and defect of the wiring har-
ness on the GND side.

When hazard relay 2 (R17) is re- No Relay (R17) is normal
3) Check the relay.
Hazard relay 2 (R17) defec- 1) Turn the starting switch OFF.

tive
3) Check the relay.
Possible causes 4) Apply voltage between R17 (male) (1) (2).
and standard value
Apply 24 V between
tween (1) (2).
Apply 24 V between
Resistance Max. 1 z
tween (1) (2).
Disconnection in wiring har- 2) Disconnect connectors R17, FLB, FLL, CM, and R16.
2
(Disconnection or defective Between R17 (female) (3) FLB Resistance Max. 1 z
contact) Wiring harness between FLL CM (female) (6)
Resistance Max. 1 z
and branching point of R16 (female) (1), (3)
HD465-7, HD605-7 20-937

(10)
b) When turn signal lever and hazard lamp switch are operated, the turn signal lamps do not flash but
light up
Trouble b) When turn signal lever and hazard lamp switch are operated,
Not set Not set MON the turn signal lamps do not flash but light up
When the turn signal lever and lamp hazard switch are operated, the turn signal lamps do not flash but
Contents of trouble
light up
Problem that When the turn signal lever and hazard lamp switch are operated, the turn signal lamps do not flash but
appears on machine light up
Related information both of them are broken, there is a grounding fault. Accordingly, check the related wiring harness.)

2) Disconnect connectors R17, FLB, FLL, CM, and R16.
1 Hot short in wiring harness Resistance between
Wiring harness between FLL, CM
Possible causes FLL, CM (female) (6),
(female) (6), R16 (female) (1) Max. 1 z
and standard value R16 (female) (1), (3)
and (3)
in normal state chassis ground
2) Replace the flasher.
2 Flasher defective If the flasher is replaced, the failure is not re-
Flasher is normal
paired.
If the flasher is replaced, the failure is repaired. Flasher is defective
20-938 HD465-7, HD605-7

(10)
c) When turn signal lever is operated, turn signal lamps on either or both sides do not flash
(When hazard lamp switch is operated, however, turn signal lamps flash normally)
c) When turn signal lever is operated, turn signal lamps on either
Trouble
Not set Not set MON or both sides do not flash (When hazard lamp switch is oper-
ated, however, turn signal lamps flash normally)
When the turn signal lever is operated, the turn signal lamps on either or both sides do not flash (When
Contents of trouble
the hazard lamp switch is operated, however, the turn signal lamps flash normally)
Problem that When the turn signal lever is operated, however, the turn signal lamps on either or both sides do not
appears on machine flash (When the hazard lamp switch is operated, the turn signal lamps flash normally)

2) Disconnect connector CM.
3) Check the lever.
Set the turn signal le-
Resistance Max. 1 z
Between CM (male) ver in LEFT.
1 Turn signal lever defective (6) (7) Set the turn signal le-
ver in RIGHT.
Set the turn signal le-
Between CM (male) ver in LEFT.
(6) (8) Set the turn signal le-
Resistance Max. 1 z
ver in RIGHT.
and standard value Between R17 (male) (1) (2) Resistance 200 400 z
in normal state
tive
3) Check the relay.
Apply 24 V between
Resistance Max. 1 z
tween (1) (2).
Apply 24 V between
Resistance Max. 1 z
tween (1) (2).
2) Disconnect connectors R17, FLB, FLL, CM, R16, and fuse BT1 ter-
Disconnection in wiring har- minal (4).
3
(Disconnection or defective Wiring harness between fuse BT1 (4), R17
Resistance Max. 1 z
contact) (female) (6), FLB
Wiring harness between CM (female) (6), FLL,
Resistance Max. 1 z
branching point of R16 (female) (1), (3)
HD465-7, HD605-7 20-939

(10)
d) When hazard lamp switch is turned ON, any turn signal lamp does not flash
(When turn signal lever is operated, however, turn signal lamps flash normally)
d) When hazard lamp switch is turned ON, any turn signal lamp
Trouble
Not set Not set MON does not flash (When turn signal lever is operated, however,
turn signal lamps flash normally)
When the hazard lamp switch is turned ON, any turn signal lamp does not flash (When turn signal lever
Contents of trouble
is operated, however, turn signal lamps flash normally).
Problem that When the hazard lamp switch is turned ON, any turn signal lamp does not flash (When turn signal lever
appears on machine is operated, however, turn signal lamps flash normally).

Hazard lamp switch defec-
1 Between
tive Turn the hazard lamp switch ON. Resistance Max. 1 z
HAZ
(male) (1)
Turn the hazard lamp switch OFF. Resistance Min. 1 M z
(3)
3) Check the relay.

Possible causes 2 2) Disconnect connector R16.
and standard value tive
3) Check the relay.
in normal state 4) Apply voltage between R16 (male) (5) (6).
Apply 24 V between
Resistance Max. 1 z
tween (5) (6).
Apply 24 V between
Resistance Max. 1 z
tween (5) (6).
Hazard relay 2 (R17) defec- placed, is failure repaired?
3 Yes Relay (R17) is defective
tive
3) Check the relay.
20-940 HD465-7, HD605-7

(10)

3) Check the relay.
Apply 24 V between
Resistance Max. 1 z
Hazard relay 2 (R17) defec- Between R17 (male) (1) (2).
3 (5) (3)
tive Do not apply 24 V be-
tween (1) (2).
Apply 24 V between
Resistance Max. 1 z
tween (1) (2).
Possible causes 2) Disconnect connectors R17, FLB, FLL, CM, R16, and fuse BT1 ter-
and standard value minal (4).
Wiring harness between fuse BT1 (24) R17
Resistance Max. 1 z
(female) (5)
Wiring harness between FLL and R16 (female)
Resistance Max. 1 z
(1) (3)
(Disconnection or defective chassis ground
contact) Wiring harness between R17 (female) (2)
Resistance Max. 1 z
chassis ground
Wiring harness between fuse BT2 (24) HAZ
Resistance Max. 1 z
(female) (1)
Wiring harness between HAZ (female) (3)
Resistance Max. 1 z
R16 (female) (5)
Wiring harness between HAZ (female) (3)
Resistance Max. 1 z
R17 (female) (1)
HD465-7, HD605-7 20-941

(10)
e) When hazard lamp switch is turned OFF, turn signal lamps continue flashing
(When turn signal lever is operated, however, turn signal lamps flash normally)
e) When hazard lamp switch is turned OFF, turn signal lamps
Trouble
Not set Not set MON continue flashing (When turn signal lever is operated, howev-
er, turn signal lamps flash normally)
When the hazard lamp switch is turned OFF, the turn signal lamps continue flashing (When turn signal
Contents of trouble
lever is operated, however, turn signal lamps flash normally).
Problem that When the hazard lamp switch is turned OFF, the turn signal lamps continue flashing (When turn signal
appears on machine lever is operated, however, turn signal lamps flash normally).

Hazard lamp switch defec-
1 Between
tive Turn the hazard lamp switch ON. Resistance Max. 1 z
HAZ
(male) (1)
Turn the hazard lamp switch OFF. Resistance Min. 1 M z
(3)
3) Check the relay.

tive
in normal state
Apply 24 V between
Resistance Max. 1 z
tween (5) (6).
Apply 24 V between
Resistance Max. 1 z
tween (5) (6).
2) Disconnect connectors HAZ, R17, and R16.
Voltage between HAZ
Wiring harness between HAZ (fe- (female) (3), R16 (fe-
ground
Voltage between HAZ
Wiring harness between HAZ (fe- (female) (3), R17 (fe-
Max. 1 V
ground
20-942 HD465-7, HD605-7

(10)
f) Turn signal pilot lamps do not flash normally

(Turn signal lamps flash normally, however)
Trouble f) Turn signal pilot lamps do not flash normally (Turn signal lamps
Not set Not set MON flash normally, however)
Contents of trouble The turn signal pilot lamps do not flash normally (The turn signal lamps flash normally, however).
Problem that
The turn signal pilot lamps do not flash normally (The turn signal lamps flash normally, however).
appears on machine
both of them are broken, there is a grounding fault. Accordingly, check the related wiring harness.)
The turn signal lamps are branched at the switch and relay to the front, rear, right, and left. Accordingly,
Related information if only 1 lamp is defective, the possible causes of the failure are breakage of the bulb, defect of the

2) Disconnect connectors BTC2A and R16.
ness
1 Wiring harness between DPC2A (female) (7)
R16 (female) (4)
contact)
Resistance Max. 1 z
R16 (female) (2)
Between Set the turn signal lever in RIGHT. Max. 1 V /
Voltage
DPC2A 20 30 V (*)
2 Machine monitor defective (7) chas- Set the turn signal lever in NEU-
sis ground TRAL. Voltage Max. 1 V
Between Set the turn signal lever in NEU- Voltage Max. 1 V

DPC2A TRAL.
(7) chas- Max. 1 V /
sis ground Set the turn signal lever in LEFT. Voltage
20 30 V (*)
(*) Voltage changes alternately.
HD465-7, HD605-7 20-943

(10)
20-944 HD465-7, HD605-7

(1)
MON-10 NIGHT LIGHTING IS ABNORMAL

a) When lamp switch is set in 1st or 2nd position, any of small lamp, night lamp, and head lamp does
not light up.
Action code Failure code Controller code Night lighting is abnormal

Trouble a) When lamp switch is set in 1st or 2nd position, any of small
Not set Not set Not set lamp, night lamp, and head lamp does not light up.
When the lamp switch is set in the 1st or 2nd position, any of the small lamp, night lamp, and head
Contents of trouble
lamp does not light up.
Problem that When the lamp switch is set in the 1st or 2nd position, any of the small lamp, night lamp, and head
appears on machine lamp does not light up.
Before performing troubleshooting, check that fuses BT1 (2), BT1 (6), BT1 (8), BT1 (10), and BT1 (12)
are not broken. (If any of them is broken, there is a grounding fault. Accordingly, check the related
wiring harness.)
The lamps and night lighting are branched at the switch and relay to the related devices. Accordingly,
Related information
if only 1 device is defective, the possible causes of the failure are breakage of the bulb, defect of the

Between Set the lamp switch in OFF position. Resistance Min. 1 M z

1 Lamp switch defective CM (male) Set the lamp switch in 1st position. Resistance Max. 1 z
(1) (2) Set the lamp switch in 2nd position. Resistance Max. 1 z
Possible causes
and standard value Between Set the lamp switch in OFF position. Resistance Min. 1 M z
in normal state CM (male) Set the lamp switch in 1st position. Resistance Min. 1 M z
Disconnection in wiring har- 2) Disconnect connectors CM fuse BT1 (2)
ness 3) Insert T-adapter.
2
(Disconnection or defective 4) Turn the starting switch ON.
contact) Wiring harness between BT1 (2) Voltage between CM
20 30 V
CM (female) (1) (1) chassis ground
HD465-7, HD605-7 20-945

(10)
b) When lamp switch is set in 1st position, small lamp and night lamp do not light up

Trouble b) When lamp switch is set in 1st position, small lamp and night
Not set Not set Not set lamp do not light up
Contents of trouble When the lamp switch is set in the 1st position, the small lamp and night lamp do not light up.
Problem that
When the lamp switch is set in the 1st position, the small lamp and night lamp do not light up.
appears on machine
wiring harness.)
Related information


Possible causes
and standard value
CM (male) Set the lamp switch in 1st position. Resistance Min. 1 M z
in normal state
2) Disconnect connectors CM and fuse BT1 (2)
ness 4) Turn the starting switch ON.
2
contact) Wiring harness between CM (fe-
Voltage between CM
male) (2), DPC2B (female), 20 30 V
(2) chassis ground
branching point of BT1 (1), (11)
20-946 HD465-7, HD605-7

(10)
c) When lamp switch is OFF, small lamp and night lamp light up

Trouble
Not set Not set MON c) When lamp switch is OFF, small lamp and night lamp light up
Contents of trouble When the lamp switch is OFF, the small lamp and night lamp light up.
Problem that
When the lamp switch is OFF, the small lamp and night lamp light up.
appears on machine

Possible causes Between Set the lamp switch in OFF position. Resistance Min. 1 M z
and standard value CM (male) Set the lamp switch in 1st position. Resistance Min. 1 M z
in normal state (1) (3) Set the lamp switch in 2nd position. Resistance Max. 1 z
2) Disconnect connectors DPC2B, CM, LS, fuse BT1 (2), and ta-
chograph.
Wiring harness between CM (fe- Voltage between CM
male) (2), DPC2B (female), (female) (2) chassis Max. 1 V
branching point of BT1 (1), (11) ground
HD465-7, HD605-7 20-947

(10)
d) When dimmer switch is operated, brightness of night lighting does not change

Trouble d) When dimmer switch is operated, brightness of night lighting
Not set Not set Not set does not change
Contents of trouble When the dimmer switch is operated, the brightness of the night lighting does not change.
Problem that
When the dimmer switch is operated, the brightness of the night lighting does not change.
appears on machine
wiring harness.)
Related information

2) Disconnect connectors DPC2B, CM, fuse BT1 (9), (11), Switch, and
Tachograph.
Wiring harness between LS (female) (3)
1 chassis ground
contact) Wiring harness between LS (female) (2)
DPC2B (female) (12) (branching point of Resistance Max. 1 z
Possible causes Switch)
and standard value
Wiring harness between LS (female) (1),
in normal state
DPC2B (female) (5) branching point of BT1 Resistance Max. 1 z
(9), (11) Tachograph
2 Dimmer switch defective 5) Turn the starting switch ON.
6) Set the lamp switch in 1st position.
Between LS (1) (3) Voltage 20 30 V
Between LS (2) (3) Voltage 6 27 V
20-948 HD465-7, HD605-7

(10)
e) Head lamp "Hi" beam does not light up

Trouble
Not set Not set Not set e) Head lamp "Hi" beam does not light up
Contents of trouble The head lamp cannot be set to "Hi" or "Lo".
Problem that
The head lamp cannot be set to "Hi" or "Lo".
appears on machine
wiring harness.)
Related information



When head lamp "Lo" relay (R30) is No Relay R30
replaced, is failure repaired? Yes Relay R30
3) Check the relay.
Possible causes Head lamp "Hi" relay (R30)
and standard value 2 defective Between R30 (male) (1) (2) Resistance 200 400 z
3) Check the relay.
Apply 24 V between
Resistance Max. 1 z
tween (1) (2).
2) Disconnect connectors DPC2B, CM, fuse BT1 (9) (11), Switch,
and Tachograph
ness
3
(Disconnection or defective Wiring harness between R30 (female) (1), (3) Resistance Max. 1 z
contact) branching point of wiring harness
Resistance Max. 1 z
DCP1 (female) (14)
Resistance Max. 1 z
branching point of wiring harness
HD465-7, HD605-7 20-949

(10)
f) Head lamp "Lo" beam does not light up

Trouble
Not set Not set Not set f) Head lamp "Lo" beam does not light up
Contents of trouble The head lamp "Lo" beam does not light up.
Problem that
The head lamp "Lo" beam does not light up.
appears on machine
wiring harness.)
Related information



Possible causes
2) Disconnect connectors DPC2A, PL1, PR1, R29, CM, and fuse BT1
and standard value
terminals (5) and (6)
in normal state
Wiring harness between PL1 (female) (1)
Resistance Max. 1 z
chassis ground
Disconnection in wiring har- Wiring harness between PR1 (female) (1)
2 chassis ground
contact) Wiring harness between battery relay terminal
M (CN-02), fuse BT1 terminals (1), (2), CM Resistance Max. 1 z
(female) (1)
Wiring harness between CM (female) (3)
Resistance Max. 1 z
fuse BT1 terminal (7)
Wiring harness fuse BT1 terminal (8) PL1
Resistance Max. 1 z
(female) (1), PR1 (female) (1)
20-950 HD465-7, HD605-7

(10)
g) Head lamp cannot be set to "Hi" or "Lo"

Trouble
Not set Not set Not set g) Head lamp cannot be set to "Hi" or "Lo"
Contents of trouble The head lamp "Hi" beam does not light up.
Problem that
The head lamp "Hi" beam does not light up.
appears on machine
wiring harness.)
Related information

1 Passing switch defective Set the passing switch in RAISE
Between (PASS) position. Resistance Max. 1 z
CM (male)
Set the passing switch in RETURN
(4) (5) Resistance Min. 1 M z
(OFF) position.
When head lamp "Hi" relay (R29) No Relay R29
is replaced, is failure repaired? Yes Relay R29
3) Check the relay.
Head lamp "Passing" relay
2
3) Check the relay.
Possible causes 4) Apply voltage between R29 (male) (1) (2).
tween (1) (2).
2) Disconnect connectors DPC2A, PL2, PR2, R29, CM, and fuse BT1
terminals (5) and (6)
Wiring harness between PL2 (female) (1)
Resistance Max. 1 z
chassis ground
Wiring harness between PR2 (female) (1)
Resistance Max. 1 z
chassis ground
ness Wiring harness between fuse BT1 terminal (6)
(Disconnection or defective PL2 (female) (1), PR2 (female) (1)
contact) Wiring harness between R29 (female) (2)
Resistance Max. 1 z
chassis ground
Resistance Max. 1 z
Resistance Max. 1 z
R29 (female) (1)
Resistance Max. 1 z
HD465-7, HD605-7 20-951

(10)
h) When head lamp is set to "Hi" beam, pilot lamp of machine monitor does not light up

Trouble h) When head lamp is set to "Hi" beam, pilot lamp of machine
Not set Not set Not set monitor does not light up
Contents of trouble When the head lamp is set to "Hi" beam, the pilot lamp of the machine monitor does not light up.
Problem that
When the head lamp is set to "Hi" beam, the pilot lamp of the machine monitor does not light up.
appears on machine
wiring harness.)
Related information

Disconnection in wiring har- 2) Disconnect connectors DPC2A, CM, and R29.
1
CM (female) (5) R29 (female) (1)
and standard value 2) Disconnect connector DPC2A.
Set the passing switch
Voltage Max. 1 V
Between DPC2A (5) in "Lo".
chassis ground Set the passing switch
Voltage 20 30 V
in "Hi".
20-952 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-953

(2)
MON-11 POWER WINDOW DOES NOT OPERATE NORMALLY

a) Operating left side does not
Action code Failure code Controller code Power window does not operate normally
Trouble
Not set Not set Not set a) Operating left side does not
Contents of trouble The power window does not operate normally. (Operating left side does not)
Problem that
The power window does not operate normally. (Operating left side does not)
appears on machine
Before performing troubleshooting, check that fuses BT2 (8) are not broken. (If any of them is broken,
Related information
there is a ground fault. Accordingly, check the related wiring harness.)

Power window switch (L.H.) "Left
Between up" Resistance Min. 1 M z
R34
Power window switch (L.H.) "OFF" Resistance Min. 1 M z
Power window switch (L.H.) (male) (1)
1 (2) Power window switch (L.H.) "Left
defective Resistance Max. 1 z
down"
Power window switch (L.H.) "Left
Between up" Resistance Max. 1 z
R34
Power window switch (L.H.) "OFF" Resistance Min. 1 M z
(male) (1)
(3) Power window switch (L.H.) "Left
down"
Power window relay (R25) 3) Turn the starting switch ON.
2
defective
When power window relay (R25) is No Relay R25 is normal
replaced, is failure repaired? Yes Relay R25 is defective
2) Disconnect connectors R25, R34, PWL, and fuse BT2 terminal (8).
and standard value 4) Connect the connectors.
Wiring harness between fuse BT2 terminal (8)
Resistance Max. 1 z
R34 (female) (1)
Wiring harness between fuse BT2 terminal (8)
Resistance Max. 1 z
Disconnection in wiring har- R25 (female) (8)
contact)
Resistance Max. 1 z
CAB1 (5) PWL (female) (1)
Resistance Max. 1 z
CAB1 (6) PWL (male) (1)
Resistance Max. 1 z
R34 (female) (2)
Resistance Max. 1 z
chassis ground
2) Replace power window motor (L.H.) with motor normal one.
Power window motor (L.H.) aIf the results of 1 3 above are normal, perform the following test.
4
defective
When power window motor (L.H.) No Motor is normal
is motor replaced, is failure re-
placed ? Yes Motor is defective
20-954 HD465-7, HD605-7

(10)
b) Operating right side does not
Action code Failure code Controller code Power window does not operate normally
Trouble
Not set Not set Not set b) Operating right side does not
Contents of trouble The power window does not operate normally. (Operating right side does not)
Problem that
The power window does not operate normally. (Operating right side does not)
appears on machine
Before performing troubleshooting, check that fuses BT2 (10) are not broken. (If any of them is broken,
Related information
there is a ground fault. Accordingly, check the related wiring harness.)

Power window switch (R.H.) "Right
Between up" Resistance Min. 1 M z
R35
Power window switch (R.H.) "OFF" Resistance Min. 1 M z
Power window switch (R.H.) (male) (1)
1 (2) Power window switch (R.H.) "Right
defective Resistance Max. 1 z
down"
Power window switch (R.H.) "Right
Between up" Resistance Max. 1 z
R35
Power window switch (R.H.) "OFF" Resistance Min. 1 M z
(male) (1)
(3) Power window switch (R.H.) "Right
down"
Power window relay (R25) 3) Turn the starting switch ON.
2
defective
When power window relay (R25) is No Relay R25 is normal
replaced, is failure repaired? Yes Relay R25 is defective
2) Disconnect connectors R25, R35, PWR, and fuse BT2 terminal (10).
and standard value 4) Connect the connectors.
Resistance Max. 1 z
(10) R35 (female) (1)
Resistance Max. 1 z
Disconnection in wiring har- (10) R25 (female) (11)
contact)
Resistance Max. 1 z
CAB1 (7) PWR (female) (1)
Resistance Max. 1 z
CAB1 (8) PWR (male) (1)
Resistance Max. 1 z
R35 (female) (2)
Resistance Max. 1 z
chassis ground
2) Replace power window motor (R.H.) with motor normal one.
Power window motor (R.H.) a If the results of 1 3 above are normal, perform the following test.
4
defective
When power window motor (R.H.) No Motor is normal
is motor replaced, is failure re-
placed ? Yes Motor is defective
HD465-7, HD605-7 20-955

(10)
20-956 HD465-7, HD605-7

(2)
MON-12 DEFECTIVE AIR CONDITIONER

a) Air conditioner does not operate
Action code Failure code Controller code Defective air conditioner

Trouble
Not set Not set Not set a) Air conditioner does not operate
Contents of trouble The air conditioner does not operate.
Problem that
The air conditioner does not operate.
appears on machine
If fuse BT3 (4) is broken, check the wiring harness between fuse BT3 (4) and ACP1 (female) (1) for
Related information
ground fault.

2) Disconnect connector ACP1 and fuse BT3 (4) terminal.
1 Wiring harness between fuse BT3 (4) ACP1
and standard value (Disconnection or defective Resistance Max. 1 z
(female) (1)
in normal state contact)
Wiring harness between ACP1 (female) (14)
Resistance Max. 1 z
chassis ground
Defective air conditioner
2 a Check the control panel and repair or replace it, if it has abnormality.
control panel
HD465-7, HD605-7 20-957

(10)
b) Air does not come out or air flow cannot be adjusted

Trouble
Not set Not set Not set b) Air does not come out or air flow cannot be adjusted
Contents of trouble Air does not come out or air flow cannot be adjusted
Problem that
Air does not come out or air flow cannot be adjusted
appears on machine
Related information

2) Disconnect connectors ACR1, ACR2, ACR3, and ACR4 and fuse
terminals BT1 (18) and BT3 (4).
Wiring harness between fuse BT3 (4) ACR1
Resistance Max. 1 z
(female) (1)
Disconnection in power
supply wiring harness Wiring harness between fuse BT3 (4) ACR2
(Disconnection or defective (female) (1)
contact) Wiring harness between fuse BT3 (4) ACR3
Resistance Max. 3 z
(female) (1)
Resistance Max. 4 z
(female) (1)
Resistance Max. 1 z
(female) (3)
2) Disconnect connectors ACP1, ACR1, ACR2, ACR3, ACR4, ACR5,
ACBM, and ACRE.
Resistance Max. 1 z
ACR1 (female) (2)
Possible causes
and standard value Wiring harness between ACP1 (female) (5)
Resistance Max. 1 z
in normal state ACR2 (female) (2)
Resistance Max. 1 z
ACR3 (female) (2)
Resistance Max. 1 z
ACR4 (female) (2)
Wiring harness between ACR1 (female) (4)
Disconnection in wiring Resistance Max. 1 z
harness ACBM (female) (1)
2
(Disconnection or defective Wiring harness between ACR2 (female) (3)
Resistance Max. 1 z
contact) ACBM (female) (2), ACRE (female) (1)
Resistance Max. 1 z
ACRE (female) (2)
Resistance Max. 1 z
ACRE (female) (3)
wiring harness between ACR2 (female) (4)
Resistance Max. 1 z
chassis ground
Resistance Max. 1 z
chassis ground
Resistance Max. 1 z
chassis ground
wiring harness between ACRE (female) (4)
Resistance Max. 1 z
chassis ground
20-958 HD465-7, HD605-7

(10)

2) Disconnect connectors ACP1, ACR1, ACR2, ACR3, ACR4, ACR5,
ACBM, and ACRE.
Wiring harness between Resistance between ACR1
ACR1 (female) (4) ACBM (female) (4), ACBM (female) Min. 1 M z
3 ACR2 (female) (3) ACBM (female) (3), ACBM (female)
ness Min. 1 M z
(female) (2), ACRE (female) (2), ACRE (female) (1)
(1) chassis ground
ACR3 (female) (3) ACRE (female) (3), ACRE (female) Min. 1 M z
ACR4 (female) (3) ACRE (female) (3), ACRE (female) Min. 1 M z
2) Replace relay.
4 Defective blower main relay 4) Start air conditioner.
Replace relay Condition becomes normal. Relay is defective.
with normal one. Condition does not become normal. Relay is normal.
2) Replace relay.
5 Defective blower Hi relay 4) Start air conditioner.
Possible causes Condition becomes normal. Relay is defective.
Replace relay
and standard value
in normal state
2) Replace relay.
6 Defective blower M2 relay 4) Start air conditioner.
2) Replace relay.
7 Defective blower M1 relay 4) Start air conditioner.
2) Replace motor.
8 Defective blower motor 4) Start air conditioner.
Replace motor Condition becomes normal. Relay is defective.
2) Disconnect connector ACRE.
3) Check resistor unit.
9 Defective blower resistor Between ACRE (female) (1) (2) Resistance 2.8 z
Between ACRE (female) (1) (3) Resistance 4.8 z
Between ACRE (female) (1) (4) Resistance 4.0 z
control panel
HD465-7, HD605-7 20-959

(10)
c) Air is not cooled or temperature cannot be adjusted (Electric system)

Trouble c) Air is not cooled or temperature cannot be adjusted (Electric
Not set Not set Not set system)
Contents of trouble Air is not cooled or temperature cannot be adjusted
Problem that
Air is not cooled or temperature cannot be adjusted
appears on machine
If fuse BT3 (4) is broken, check the wiring harness between fuse BT3 (4) and ACP1 (female) (1) for
Related information ground fault. If fuse BT1 (18) is broken, check the wiring harness between fuse BT1 (18) and ACR5
(female) (3) for grounding fault.

2) Disconnect connectors ACR5 and fuse terminals BT1 (18) and BT3 (4).
Disconnection in power 3) Connect T-adapter.
supply wiring harness
1 Wiring harness between fuse BT3 (4) ACR5
(female) (1)
contact)
Resistance Max. 1 z
(female) (3)
2) Disconnect connectors ACP1, ACP2, ACM1, ACM2, ACM3, ACTH,
ACPS, and E07.
Resistance Max. 1 z
ACPS (female) (2)
Resistance Max. 1 z
ACTH (female) (1)
Resistance Max. 1 z
ACM1(female) (4)
Disconnection in wiring har- ACTH (female) (2) Resistance Max. 1 z
2 ness (Disconnection or de-
fective contact) Resistance Max. 1 z
Possible causes ACM1 (female) (3)
and standard value Wiring harness between ACP1 (female) (16)
ACM1 (female) (1)
Resistance Max. 1 z
ACM1 (female) (2)
Resistance Max. 1 z
ACM1 (female) (5)
Resistance Max. 1 z
ACPS (female) (1)
Resistance Max. 1 z
E07 (female) (1)
2) Disconnect connectors ACP1, ACP2, ACM1, ACM2, ACM3, ACTH,
ACPS, and E07.
Wiring harness between Resistance between ACP1
ACP1 (female) (6) ACPS (female) (6), ACPS (female) Min. 1 M z
3
ness
ACP1 (female) (9) ACTH (female) (9), ACTH (female) Min. 1 M z
ACP1 (female) (10) ACM1 (female) (10), ACM1 (female) Min. 1 M z
20-960 HD465-7, HD605-7

(10)

ACP1 (female) (13) ACTH (female) (13), ACTH (female) Min. 1 M z
ACP1 (female) (13) ACM1 (female) (13), ACM1(female) Min. 1 M z
3
ness
ACR5 (female) (2) ACPS (female) (2), ACPS (female) Min. 1 M z
ACR5 (female) (4) E07 (fe- (female) (4), E07 (female) Min. 1 M z
male) (1) (1) chassis ground
2) Replace relay.
Defective compressor clutch
4 4) Start air conditioner.
Possible causes relay
and standard value Replace relay Condition becomes normal. Relay is defective.
in normal state with normal one. Condition does not become normal. Relay is normal.
2) Disconnect connector ACPS.
5 Defective pressure switch
Air conditioner switch OFF Resistance Min. 1 M z
Between ACPS
(male) (1) (2) Air conditioner switch ON in Resistance Max. 1 z
cooling mode
2) Disconnect connector ACTH.
6 Defective thermistor 4) Start air conditioner.
Between ACTH (male) Temperature: 25C Resistance 37 50 k z
(1) (2) Temperature: 100C Resistance 3.5 4.0 k z
2) Replace motor.
Defective temperature ad-
7 4) Start air conditioner.
justment servomotor
Replace motor Condition becomes normal. Motor is defective.
with normal one. Condition does not become normal. Motor is normal.
2) Replace air conditioner compressor.
Defective air conditioner 4) Start air conditioner.
8
compressor Replace air Condition becomes normal. Compressor is defective.
conditioner
compressor with Condition does not become Compressor is normal.
normal one. normal.
HD465-7, HD605-7 20-961

(10)

2) Replace diode (E08).
Possible causes
9 Defective diode (E08) Replace diode Condition becomes normal. Diode (E08) is defective.
and standard value
in normal state (E08) with Condition does not become
normal one. Diode (E08) is normal.
normal.
control panel
d) Recirculated air and fresh air cannot be selected

Trouble
Not set Not set Not set d) Recirculated air and fresh air cannot be selected
Contents of trouble Recirculated air and fresh air cannot be selected because of a defect in the air conditioner system.
Problem that
Recirculated air and fresh air cannot be selected.
appears on machine
Related information

2) Disconnect connectors ACP2 and ACM3.
Disconnection in wiring 3) Connect T-adapter.
harness
1 Wiring harness between ACP2 (female) (5)
ACM3 (female) (2)
contact)
Resistance Max. 1 z
ACM3 (female) (5)
Possible causes 1) Turn starting switch OFF.
and standard value 2) Disconnect connectors ACP2 and ACM3.
2 ACP2 (female) (5) ACM3 (female) (5), ACM3 (female) Min. 1 M z
ness
control panel
20-962 HD465-7, HD605-7

(10)
e) Air outlets cannot be selected

Trouble
Not set Not set Not set e) Air outlets cannot be selected
Contents of trouble Air outlets cannot be selected
Problem that
Air outlets cannot be selected
appears on machine
Related information

2) Disconnect connectors ACP1, ACP2, and ACM2.
Resistance Max. 1 z
ACM2 (female) (4)
Disconnection in wiring Wiring harness between ACP1 (female) (13)
harness Resistance Max. 1 z
1 ACM2 (female) (3)
ACM2 (female) (2)
Resistance Max. 1 z
ACM2 (female) (5)
Resistance Max. 1 z
ACM2 (female) (1)
2) Disconnect connectors ACP1, ACP2, and ACM2.
and standard value
in normal state
2
ness Wiring harness between Resistance between ACP2
control panel
HD465-7, HD605-7 20-963

(10)
20-964 HD465-7, HD605-7

(5)
f) Air is not cooled (Mechanical system)

Trouble
Not set Not set Not set f) Air is not cooled (Mechanical system)
Contents of trouble Air is not cooled because of abnormality in mechanical system.
Problem that
Air is not cooled because of abnormality in mechanical system.
appears on machine
Related information

Gas leakage through pipe
1 Check and repair or replace, if abnormal.
joints or parts
Natural leakage through
hose, etc. (Refrigerant has Check refrigerant level and add new refrigerant to proper level, if nec
2
not been added for long essary.
time)
3 Insufficient refrigerant level Add new refrigerant to proper level.
Check and repair or replace, if abnormal.
4 Defective expansion valve a Check the valve for excessive opening and defective contact of
heat-sensor tube, too.
Clogging of low-pressure
5 Check and remove clogging material, if there is any, or replace.
circuit and evaporator
Check and remove clogging material, if there is any, and clean evap-
Possible causes 6 Clogging of evaporator fins
orator.
and standard value
in normal state 7 Clogging of filter Check and clean, or replace.
Defective installation of ther-
mistor
Air leakage through air con-
9 Check and repair or replace leaking part.
ditioner unit and duct
10 Insufficient set air flow Increase set air flow.
11 Excessive refrigerant Check refrigerant level and reduce it to proper level, if necessary.
Evacuate system and fill it with refrigerant to proper level and replace
12 Entry of air
receiver drier.
13 Clogging of condenser fins Check fins for clogging and clean them, if necessary.
Insufficient compression by
14 Check and repair or replace, if necessary.
compressor
Entry of water in refrigerant Evacuate system and fill it with refrigerant to proper level and replace
15
circuit receiver drier.
HD465-7, HD605-7 20-965

(10)
g) Air is not heated (Defective hot water circuit)

Trouble
Not set Not set Not set g) Air is not heated (Defective hot water circuit)
Contents of trouble Air is not heated (Defective hot water circuit).
Problem that
Air is not heated (Defective hot water circuit).
appears on machine
Check that water is not leaking through the hot water circuit.
Related information
Check that air is flowing out of the air outlets.

Check heater core fins for clogging and clean them, if necessary.
1 Clogging of heater core fins a If this is the cause, the temperature at the hot water inlet and outlet
of the heater core becomes high.
Check and repair or replace leaking part.
Air leakage through air con-
2 a If this is the cause, the temperature at the hot water inlet and outlet
ditioner unit
of the heater core becomes high.
Possible causes Check and remove clogging material, or replace valve.
and standard value 3 Defective water valve a If this is the cause, the temperature at the hot water inlet of the heat-
in normal state (Clogging or defective valve)
er core becomes high but that at the hot water outlet becomes low.
a If this is the cause, the temperature at the hot water inlet of the heat-
4 Clogging of heater core
er core becomes high but that at the hot water outlet becomes low.

Clogging up to hot water
5 a If this is the cause, the temperature at the hot water inlet of the heat-
inlet of heater core
er core becomes low.
h) Abnormal sound comes out

Trouble
Not set Not set Not set h) Abnormal sound comes out
Contents of trouble Abnormal sound comes out.
Problem that
Abnormal sound comes out.
appears on machine
Related information

Defective installation of bolts
1 Check and repair, if abnormal.
(screws) related to case
Interference of fan case, etc.
or breakage of fan
Entry of foreign matter in
Possible causes 3 blower motor or defective Check and remove foreign matter, if there is any, and repair or replace
and standard value blower motor
in normal state Check and replace, if abnormal sound (peep or gas leakage sound)
4 Defective expansion valve
comes out.
Loosened or worn
5 Check and repair or replace, if loosened or worn.
compressor V-belt
Insufficient or excessive Check refrigerant level and reduce or increase it to proper level, if
6
refrigerant necessary.
7 Defective compressor Check and repair or replace, if abnormal.
20-966 HD465-7, HD605-7

(10)
i) Water leaks

Trouble
Not set Not set Not set i) Water leaks
Contents of trouble Water leaks.
Problem that
Water leaks.
appears on machine
Related information

Clogging of water drain hole
1 Check and repair, if abnormal.
in air conditioner unit
Clogging, bend, defective
installation, or breakage of
drain hose of air conditioner
unit
Possible causes Breakage (Cracking) of air
and standard value 3 conditioner unit case Check and repair or replace, if broken (cracked).
in normal state
Defective installation of bolts
4 (screws) related to air Check and repair or replace, if abnormal.
conditioner unit case
Defective joints of hot water
circuit piping
6 Defective heater core Check and repair or replace, if abnormal.
7 Defective water valve Check and repair or replace, if abnormal.
HD465-7, HD605-7 20-967

(10)
TROUBLESHOOTING OF VHMS CONTROLLER
SYSTEM (VHMS MODE)
Electricahot short in wiring harnessl system diagram related VHMS controller ........................................ 20-1002
Information given in troubleshooting chart ................................................................................................ 20-1004
Phenomenon type code list....................................................................................................................... 20-1005
[A000N1] (or VHMS_LED displays [n201]) Engine overrun ............................................................. 20-1006
[DBB0KK] (or VHMS_LED indicates "n901") Abnormality in source voltage.................................. 20-1006-1
[DBB5KP] (or VHMS_LED indicates "n904") Abnormality in sensor power source (5 V) system.... 20-1006-3
[DBB6KP] (or VHMS_LED indicates "n902") Abnormality in sensor power source (24V) system... 20-1006-5
[DBB7KP] (or VHMS_LED indicates "n903") Abnormality in sensor power source (12V) system... 20-1006-7
[DBBRKR] (or VHMS_LED displays [n801]) Defective CAN communications:
Defective communications (KR)
(between engine controller and VHMS controller)............................................................ 20-1007
[DBBSKR] (or VHMS_LED displays [n803]) Defective S-NET communications: (KR) ...................... 20-1009
[DGE1KB] (or VHMS_LED displays [n242]) Disconnection, short circuit with chassis ground
in engine oil temperature sensor system (KB) {30 min (at 500 rpm or above) after
starting engine}..................................................................................................................20-1011
[DGE1KY] (or VHMS_LED displays [n241]) Short circuit with power source (Hot short)
in engine oil temperature sensor system (KY).................................................................. 20-1012
[DGE5KX] (or VHMS_LED displays [n401]) Failure in ambient temperature sensor system:
Input signal outside range (KX) ........................................................................................ 20-1013
[DGT4KA] (or VHMS_LED displays [n312]) Disconnection, short circuit with chassis ground
in No. 1, 2, 3 (front) exhaust temperature sensor system (KA) ........................................ 20-1014
[DGT4KB] (or VHMS_LED displays [n311]) Short circuit with power source in (Hot short)
No. 1, 2, 3 (front) exhaust temperature sensor system (KB) ............................................ 20-1016
[DGT5KA] (or VHMS_LED displays [n322]) Disconnection, short circuit with chassis ground
in No. 4, 5, 6 (rear) exhaust temperature sensor system (KA) ......................................... 20-1018
[DGT5KB] (or VHMS LED displays [n321]) Short circuit with power source (Hot short)
in No. 4, 5, 6 (rear) exhaust temperature sensor system (KB) ......................................... 20-1020
[DHE5KB] (or VHMS_LED displays [n332]) Disconnection, short circuit with chassis ground
in engine blow-by pressure sensor system (KA) .............................................................. 20-1022
[DHE5KY] (or VHMS_LED displays [n331]) Short circuit with power source (Hot short)
in engine blow-by pressure sensor system (KY) .............................................................. 20-1023
[DhP4KX] Suspension pressure sensor (Front right): Out of input signal range (KX).................... 20-1023-1
[DhP5KX] Suspension pressure sensor (Front left): Out of input signal range (KX) ...................... 20-1023-3
[DhP6KX] Suspension pressure sensor (Rear right): Out of input signal range (KX) .................... 20-1023-5
[DhP7KX] Suspension pressure sensor (Rear left): Out of input signal range (KX)....................... 20-1023-7
[DKH1KX] Pitch angle sensor: Out of input signal range (KX)........................................................ 10-1023-9
[F@BBZL] (or VHMS_LED displays [n338]) Engine blow-by pressure is high: (ZL) .......................... 20-1024
[F@BYNR] (or VHMS_LED displays [n362]) No. 1, 2, 3 (front) exhaust temperature is high
(2):(NR)............................................................................................................................. 20-1025
[F@BYNS] (or VHMS_LED displays [n361]) No. 1, 2, 3 (front) exhaust temperature is high
(1):(NS)............................................................................................................................. 20-1026
[F@BZNR] (or VHMS_LED displays [n372]) No. 4, 5, 6 (rear) exhaust temperature is high
(2):(NR)............................................................................................................................. 20-1027
[F@BZNS] (or VHMS_LED displays [n371]) No. 4, 5, 6 (rear) exhaust temperature is high
(1):(NS)............................................................................................................................. 20-1028
VHMS-1 VHMS-1 Abnormality in satellite data communication
a) Satellite communication data are not transmitted ......................................................... 20-1029
b) Abnormality in downloading into PC or setting of PC ................................................... 20-1032
VHMS-2 Abnormality in saving data in VHMS controller ................................................................. 20-1034
VHMS-3 Engine blow-by pressure indicated by monitor is low........................................................ 20-1036
HD465-7, HD605-7 20-1001

(10)
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED VHMS CONTROLLER
ELECTRICAL SYSTEM DIAGRAM RELATED VHMS CONTROLLER
20-1002 HD465-7, HD605-7

(5)
HD465-7, HD605-7 20-1003

(5)
20-1003-1 HD465-7, HD605-7

(5)
TROUBLESHOOTING INFORMATION GIVEN IN TROUBLESHOOTING CHART
INFORMATION GIVEN IN TROUBLESHOOTING CHART

a The following type of information is given in the troubleshooting charts and related circuit diagrams, so make
sure that you understand the content fully before starting troubleshooting.
Shown on panel Shown on Shown on Trouble Problem that appeared on machine
display panel display panel display
Contents of trouble Condition when monitor panel or controller detected failure.
Action of controller Action taken to protect system or equipment when monitor panel or controller detected failure.
Problem that
Problem that appeared on machine when monitor panel or controller took above action.
appears on machine
Related information Information related to troubleshooting or failure that occurred.

<Content of information>
Standard value when condition is normal (used to judge status of
probable failure).
1 Remarks used to judge status of probable failure.
<Problems with wiring harness>

Disconnection
Defective connection of connector or disconnection in wiring har-
ness.
2 Ground fault
Wiring harness not connected to GND (ground) circuit is in contact
with GND circuit.
Wiring harness not connected to power source (24V) circuit is in
contact with power source circuit.
Probable cause Probable cause of existing Short circuit
and standard value 3 failure (the numbers are Wiring harnesses of independent circuits are in abnormal contact.
when normal index numbers and do not
indicate the order of priority) <Precautions when troubleshooting>
1) Method of displaying connector No. and method of handling T-
adapter
If there are no special instructions, insert or connect the T-adapter
as follows.
4 If there is no indication of (male) or (female) with the connector
No., disconnect the connector and insert the T-adapter into both
the male and female sides.
If (male) or (female) is indicated with the connector No., discon-
nect the connector and insert the T-adapter into only the side indi-
cated (either male or female).
2) Order of listing pin No. and method of handling test lead
5 If there are no special instructions, connect the (+) lead and () lead
of the tester as follows.
Connect the (+) lead to the pin No. or wiring harness given first.
Connect the () lead to the pin No. or wiring harness given last.
20-1004 HD465-7, HD605-7

(10)
TROUBLESHOOTING PHENOMENON TYPE CODE LIST
This is the section of the circuit diagram that shows the parts related to the failure.
Connector No.: (type No. of pins) (color).
Arrows ( ): Shows approximate mounting position on machine.
PHENOMENON TYPE CODE LIST

a For phenomenon type codes marked "See list", refer to this list.
code code
KA Disconnection L0 Fill signal for non-existent combination of clutches ON simulta-

neously for 2 or more channels.
KB Short circuit L1 Fill signal ON when command current to ECMV is OFF.
KK Drop in power source volt- L2 Fuel pressure is higher than max. specified value.
age, input
KQ Mismatch in model selec- L3 Target components cannot be controlled.

tion signal
KR Defective communications L4 ON/OFF signals from 2 systems do not match.
Abnormality inside con- Engine speed signal, C terminal signal, oil pressure switch,
KT troller L6 coolant temperature sensor signals do not match operating
condition or stopped condition.
KX Input signal outside range L8 Analog signals of 2 systems do not match.
KY Short circuit with power LC Speed signals of 2 systems do not match.

source (Hot short)
KZ Disconnection or short cir- LD Switch remains pressed for length of time unthinkable for nor-
cuit mal operations .
MA Defective function LH Fill signal is turned OFF when command current to ECMV is
ON.
MB Drop in function
MW Slippage
NS Overheat
ZG Drop in oil pressure
ZK Drop in level
HD465-7, HD605-7 20-1005

(10)
TROUBLESHOOTING [A000N1]
[A000N1] (OR VHMS_LED DISPLAYS [n201]) ENGINE OVERRUN

Trouble Engine overrun
Not set A000N1 Not set
Contents of trouble Engine speed of more than 2,625 rpm is detected when engine is running.
Action of controller Carries out control for default mode.
Problem that
If machine continues to be used as it is, engine may be damaged.
appears on machine
Engine speed can be checked with monitoring function (code: 01001)
LED display is [n201]
Related information
If failure codes [C115KZ] or [C121LC] related to engine controller are displayed, carry out troubleshoot-
ing first for the applicable code.

1 Engine overrun Inspect engine and repair if any abnormality is found.
Defective engine speed
Probable cause 2 Carry out troubleshooting for failure code [C115KZ] or [C121LC].
sensor
and standard value
when normal 1) Start engine.
2) Check with monitoring function (code: 01001).
3 Defective VHMS controller
Monitoring code:
High idle speed Power mode 2,270 50 rpm
01001
20-1006 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DBB0KK]
[DBB0KK] (OR VHMS_LED INDICATES "n901") ABNORMALITY IN SOURCE

VOLTAGE

Trouble Abnormality source voltage
Not set DBB0KK Not set
Contents of trouble The switch source voltage is below 9.5( 2.5)V or above 42.4( 6)V.
Problem that
The system may not operate normally.
appears on machine
Related information VHMS controller LED indicates "n901".

If the circuit breaker is turned OFF, the circuit probably has ground-
1 Defective circuit breaker
ing fault (See cause 3).
2) Disconnect connector HM-CN1 and battery relay terminal CN-02
(Terminal M).
Disconnection in wiring har- Wiring harness between HM-CN1 (female) (8),
2 ness (Disconnection or de- (9) battery relay CN-02 (Terminal M) Resistance Max. 1 z
fective contact)
Wiring harness between HM-CN1 (female)
Resistance Max. 1 z
(11), (12) ER
Wiring harness between HM-CN1 (female)
Probable cause Resistance Max. 1 z
(19), (20) ER
and standard value
when normal
2) Disconnect connector HM-CN1, battery relay terminal CN-02
(Terminal M), and connectors related to them.
3 Wiring harness between Resistance between HM-
ness
HM-CN1 (female) (8), (9) CN1 (female) (8), (9) chas-
battery relay CN-02 (Termi- sis ground Min. 1 M z
nal M) and wiring harnesses
related to it
2) Disconnect HM-CN1.
4 Defective VHMS controller 3) Connect T-adapter.
Between HM-CN1 (8), (9) chassis ground Voltage 20 30 V
HD465-7, HD605-7 20-1006-1

(10)
TROUBLESHOOTING [DBB0KK]
20-1006-2 HD465-7, HD605-7

(5)
TROUBLESHOOTING [DBB5KP]
[DBB5KP] (OR VHMS_LED INDICATES "n904") ABNORMALITY IN SENSOR POWER

SOURCE (5 V) SYSTEM

Trouble Abnormality in sensor power source (5 V) system
Not set DBB5KP Not set
Contents of trouble Sensor power source (5 V) voltage is out of the normal range (4.5 5.5 V).
Problem that
appears on machine

2) Disconnect connectors HM-CN1 and HM-12.
1 Wiring harness between Resistance between HM-
ness
HM-CN1 (female) (4), (5) CN1 (female) (4), (5), HM-
Min. 1 M z
HM-12 (female) (B) CN12 (female) (B) chassis
ground
Probable cause
2) Disconnect connectors HM-CN1 and HM-12.
and standard value
when normal
Wiring harness between Voltage between HM-CN1
HM-CN1 (female) (4), (5) (female) (4), (5), HM-12 (fe- Max. 1 V
HM-12 (female) (B) male) (B) chassis ground
2) Disconnect connector HM-CN1.
Between HM-CN1 (4), (5) (11), (12) Voltage 4.5 5.5 V
HD465-7, HD605-7 20-1006-3

(10)
20-1006-4 HD465-7, HD605-7

(5)

SOURCE (24 V) SYSTEM

Contents of trouble Sensor power source (24 V) voltage is out of the normal range (20 - 30V).
Problem that
appears on machine

2) Disconnect connectors HM-CN1, HM-23A, HM-23B, SUFR, SUFL,
SURR, and SURL.
Wiring harness between Resistance between HM-
HM-CN1 (female) (2) HM- CN1 (female) (2), HM-23A
Min. 1 M z
23A (female) (A), HM-23B (female) (A), HM-23B (fe-
Ground fault in wiring har- (female) (A) male) chassis ground
1
ness Wiring harness between Resistance between HM-
HM-CN1 (female) (2) HM- CN1 (female) (2), HM-SUFL
Min. 1 M z
SUFL (female) (B), HM- (female) (B), HM-SUFR (fe-
SUFR (female) (B) male) (B) chassis ground
Wiring harness between HM- Resistance between HM-
CN1 (female) (2) HM- CN1 (female) (2), HM-SURL
Min. 1 M z
SURL (female) (B), HM- (female) (B), HM-SURR (fe-
SURR (female) (B) male) (B) chassis ground
Probable cause 2) Disconnect connectors HM-CN1, GR-2, HM-23A, HM-23B, SUFR,
and standard value SUFL, SURR, and SURL.
when normal 3) Connect T-adapter.
HM-CN1 (female) (2) HM- (female) (2), HM-23A (fe-
Max. 1 V
23A (female) (A), HM-23B male) (A), HM-23B (female)
2 Hot short in wiring harness (female) (A) (A) chassis ground
HM-CN1 (female) (2) HM- (female) (2), HM-SUFL (fe-
Max. 1 V
SUFL (female) (B), HM- male) (B), HM-SUFR (fe-
SUFR (female) (B) male) (B) chassis ground
HM-CN1 (female) (2) HM- (female) (2), HM-SURL (fe-
Max. 1 V
SURL (female) (B), HM- male) (B), HM-SURR (fe-
SURR (female) (B) male) (B) chassis ground
2) Disconnect connector HM-CN1.
Between HM-CN1 (2) (11), (12) Voltage 20 30 V
HD465-7, HD605-7 20-1006-5

(10)
20-1006-6 HD465-7, HD605-7

(5)

SOURCE (12 V) SYSTEM

Contents of trouble Sensor power source (12 V) voltage is out of the normal range (10 15 V).
Problem that
appears on machine

2) Disconnect connectors HM-CN1 and GDL.
1
ness Wiring harness between Resistance between HM-
HM-CN1 (female) (3) GDL CN1 (female) (3), GDL Min. 1 M z
(male) (1) (male) (1) chassis ground
Probable cause 2) Disconnect connectors HM-CN1 and GDL.
when normal 2 Hot short in wiring harness 4) Turn starting switch ON.
HM-CN1 (female) (3) GDL (female) (3), GDL (male) (1) Max. 1 V
(male) (1) and chassis ground
2) Disconnect HM-CN1.
3 Defective VHMS controller 3) Insert T-adapter.
Between HM-CN1 (3) (11), (12) Voltage 10 15V
HD465-7, HD605-7 20-1006-7

(10)
20-1006-8 HD465-7, HD605-7

(5)
TROUBLESHOOTING [DBBRKR]
[DBBRKR] (OR VHMS_LED DISPLAYS [n801]) DEFECTIVE CAN COMMUNICATIONS:

DEFECTIVE COMMUNICATIONS (KR)
(BETWEEN ENGINE CONTROLLER AND VHMS CONTROLLER)
Action code Failure code Controller code Defective CAN communications: Defective communications (KR)
Trouble
E03 DBBRKR Not set (between engine controller and VHMS controller)
Contents of trouble Communications (CAN) data from engine controller cannot be obtained.
Action of controller Maintains condition existing when abnormality occurred.
Problem that
VHMS function for obtaining data from engine controller not working.
appears on machine
Related information If failure code [DASRKR] related to CAN communications is displayed, carry out troubleshooting first
for the applicable code.

2) Disconnect connectors HM-CN4A and CAN1.
harness
1 Wiring harness between HM-CN4A (female)
(disconnection, defective Resistance Max. 1 z
(4) CAN1 (female) (A)
contact)
Wiring harness between HM-CN4A (female)
Resistance Max. 1 z
(12) CAN1 (female) (B)
2) Disconnect connectors HM-CN4A and CAN1.
Resistance between HM-
Wiring harness between
CN4A (female) (4), CAN1
Ground fault in wiring har- HM-CN4A (female) (4) Max. 1 z
2 (female) (A) chassis
ness CAN1 (female) (A)
ground
CN4A (female) (12), CAN1
Probable cause HM-CN4A (female) (12) Max. 1 z
(female) (B) chassis
and standard value CAN1 (female) (B)
ground
when normal
2) Disconnect connector HM-CN4A.
Wiring harness between Voltage between HM-CN4A
HM-CN4A (female) (4) (female) (4), CAN1 (female) Max. 1 V
CAN1 (female) (A) (A) chassis ground
HM-CN4A (female) (12) (female) (12), CAN1 (fe- Max. 1 V
CAN1 (female) (B) male) (B) chassis ground
2) Replace VHMS controller.
4 Defective VHMS controller Does not communicate VHMS controller
Is communication normally normal
normal when VHMS
controller is replaced? Communicates VHMS controller
normally defective
HD465-7, HD605-7 20-1007

(10)
TROUBLESHOOTING [DBBRKR]
20-1008 HD465-7, HD605-7

(2)
TROUBLESHOOTING [DBBSKR]
[DBBSKR] (OR VHMS_LED DISPLAYS [n803]) DEFECTIVE S-NET COMMUNICATIONS:

(KR)

Trouble Defective S-NET communications: (KR)
E03 DBBSKR Not set
Contents of trouble Communications data from controller cannot be obtained.
Action of controller Machine monitor shows abnormal display screen (red) to warn operator of abnormality.
Problem that
In some cases, system does not work normally.
appears on machine
If failure code [DAQSKR], [DBISKR] related to S-NET of other controllers is displayed, carry out trou-
Related information bleshooting first for the applicable code.

2) Disconnect connectors HM-CN3A, JCB, JCC, and JCD.
Disconnection in wiring Wiring harness between HM-CN3A (female)
1 (8) JCB (female) (8)
(disconnection, defective
(18) JCD (female) (4)
Resistance Max. 1 z
(9) ,(17) JCC (female) (4), JCE (female) (4)
2) Disconnect connectors HM-CN3A, JCB, and JCD.
Ground fault in wiring har- HM-CN3A (female) (8) CN3A (female) (8), JCB (fe- Min. 1 Mz
2
ness JCB (female) (8) male) (8) chassis ground
Probable cause Resistance between HM-

and standard value CN3A (female) (18), JCD
HM-CN3A (female) (18) Min. 1 Mz
when normal (female) (4) chassis
JCD (female) (4)
ground
2) Disconnect connector HM-CN3A, JCB, and JCD.
3 Hot short in wiring harness HM-CN3A (female) (8) (female) (18), JCB (female) Max. 1 V
JCB (female) (8) (8) chassis ground
HM-CN3A (female) (18) (female) (18), JCD (female) Max. 1 V
JCD (female) (4) (4) chassis ground
4 Defective VHMS controller 4) Connect connector.
Between HM-CN3A (8) (17) Voltage Max. 6 9 V
Between HM-CN3A (18) (17) Voltage Max. 6 9 V
HD465-7, HD605-7 20-1009

(10)
TROUBLESHOOTING [DBBSKR]
20-1010 HD465-7, HD605-7

(2)
TROUBLESHOOTING [DGE1KB]
[DGE1KB] (OR VHMS_LED DISPLAYS [n242]) DISCONNECTION, SHORT CIRCUIT WITH

CHASSIS GROUND IN ENGINE OIL TEMPERUTURE SENSOR SYSTEM (KB)
{30 MIN (AT 500 RPM OR ABOVE) AFTER STARTING ENGINE}
Action code Failure code Controller code Disconnection, short circuit with chassis ground in engine oil
Trouble temperature sensor system (KB)
Not set DGE1KB Not set {30 min (at 500 rpm or above) after starting engine}
Contents of trouble Signal voltage of engine oil temperature sensor has dropped below 0.3V.
Problem that
Engine oil temperature cannot be monitored with monitoring function.
appears on machine
Engine oil temperature can be checked with monitoring function (code: 42700).
Related information

2) Disconnect connector HM-31.
Defective engine oil 4) Connect connector.
1
temperature sensor 5) Turn starting switch ON.
Between HM-31 (male) (1) 25 C Resistance Approx. 35 50 kz
(2) 100 C Resistance Approx. 3.3 4.3 kz
2) Disconnect connectors HM-CN2A and HM-31.
harness
Probable cause (3) HM-31 (female) (1)
contact)
and standard value Wiring harness between HM-CN2A (female)
when normal Resistance Max. 1 z
(12) HM-31 (female) (2)
2) Disconnect connector HM-CN2A and HM-31.
3 Resistance between HM-
ness Wiring harness between
CN2A (female) (3), HM-31
HM-31 (female) (1)
ground
Between HM-CN2A (female) 25 C Resistance Approx. 35 50 kz
(3) (12) 100 C Resistance Approx. 3.3 4.3 kz
HD465-7, HD605-7 20-1011

(10)
TROUBLESHOOTING [DGE1KY]
[DGE1KY] (OR VHMS_LED DISPLAYS [n241]) SHORT CIRCUIT WITH POWER

SOURCE (HOT SHORT) IN ENGINE OIL TEMPERATURE SENSOR SYSTEM
(KY)
Action code Failure code Controller code Short circuit with power source (Hot short) in engine oil temper-
Trouble
Not set DGE1KY Not set ature sensor system (KY)
Contents of trouble Signal voltage of engine oil temperature sensor has risen above 4.9V.
Problem that
Engine oil temperature cannot be monitored with monitoring function.
appears on machine
Engine oil temperature can be checked with monitoring function (code: 42700).
Related information

Defective engine oil 4) Connect connector.
1
temperature sensor 5) Turn starting switch ON.
Between HM-31 (male) (1) 25 C Resistance Approx. 35 50 kz
(2) 100 C Resistance Approx. 3.3 4.3 kz
Probable cause 1) Turn starting switch OFF.
and standard value 2) Disconnect connectors HM-CN2A and HM-31.
when normal 3) Connect T-adapter.
HM-CN2A (female) (3) (female) (3), HM-31 (female) Max. 1 V
HM-31 (female) (1) (1) chassis ground
Between HM-CN2A (female) 25 C Resistance Approx. 35 50 kz
(3) (12) 100 C Resistance Approx. 3.3 4.3 kz
20-1012 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DGE5KX]
[DGE5KX] (OR VHMS_LED DISPLAYS [n401]) FAILURE IN AMBIENT TEMPERATURE

SENSOR SYSTEM: INPUT SIGNAL OUTSIDE RANGE (KX)
Action code Failure code Controller code Failure in ambient temperature sensor system: Input signal out-
Trouble
Not set DGE5KX Not set side range (KX)
Contents of trouble Input signal voltage of ambient temperature sensor is more than 4.9V or less than 0.3V.
Problem that
Ambient temperature cannot be monitored with monitoring function.
appears on machine
Ambient temperature can be checked with monitoring function (code: 37501).
Related information

Defective ambient
temperature sensor
0 C Resistance Approx. 10 15 kz
Between HM-35 (male) (1)
(2)
harness
Probable cause (10) HM-35 (female) (1)
contact)
and standard value Wiring harness between HM-CN2A (female)
when normal Resistance Max. 1 z
(12) HM-35 (female) (2)
3 Resistance between HM-
ness Wiring harness between
HM-35 (female) (1)
ground
4 Defective VHMS controller 0 C Resistance Approx. 10 15 kz
Between HM-CN2A (female)
(10) (12)
HD465-7, HD605-7 20-1013

(10)
TROUBLESHOOTING [DGT4KA]
[DGT4KA] (OR VHMS_LED DISPLAYS [n312])

DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN NO. 1, 2, 3
(FRONT) EXHAUST TEMPERATURE SENSOR SYSTEM (KA)
Action code Failure code Controller code Disconnection, short circuit with chassis ground in No. 1, 2, 3
Trouble
Not set DGT4KA Not set (front) exhaust temperature sensor system (KA)
Contents of trouble Signal voltage of less than 0.3V detected from No. 1, 2, 3 (front) exhaust temperature sensor.
Problem that
No. 1, 2, 3 (front) exhaust temperature cannot be monitored with monitoring function.
appears on machine
No. 1, 2, 3 (front) exhaust temperature can be checked with monitoring function (code: 42600).
Related information
LED display is [n312].

2) Replace No. 1, 2, 3 (front) exhaust temperature sensor.
Defective No. 1, 2, 3 (front) Exhaust temperature sensor
1 Does not become normal when replaced
exhaust temperature sensor normal
Exhaust temperature sensor
Becomes normal when replaced
defective
2) Disconnect connector HM-23A.
Defective No. 1, 2, 3 (front) 4) Connect connector.
2 exhaust temperature sensor 5) Start engine.
amp
Between (A) (C) Voltage 20 30 V
HM-23A Between (B) 20 C Voltage Approx. 0.9 1.2 V
(C) 500 C Voltage Approx. 2.6 3.5 V
2) Disconnect connectors HM-CN1, HM-CN2A, HM-21A, HM-22A, and
HM-23A.
Probable cause 3) Connect T-adapter.
and standard value
Wiring harness between HM-CN1 (female) (2)
when normal Disconnection in wiring Resistance Max. 1 z
harness HM-23A (female) (A)
3
(disconnection, defective Wiring harness between HM-CN2A (female)
(7) HM-23A (female) (B)
Wiring harness between HM-22A (female) (1)
Resistance Max. 1 z
HM-21A (female) (1)
Wiring harness between HM-22A (female) (2)
Resistance Max. 1 z
HM-21A (female) (2)
2) Disconnect connectors HM-CN1, HM-CN2A, HM-21A, HM-22A, and
HM-23A.
Ground fault in wiring har- CN1 (female) (2), HM-23A
4 HM-CN1 (female) (2) HM- Min. 1 Mz
ness (female) (A) chassis
23A (female) (A)
ground
CN2A (female) (7), HM-23A
HM-23A (female) (B)
ground
20-1014 HD465-7, HD605-7

(10)

2) Disconnect connectors HM-CN1 and HM-CN2A.
Probable cause 3) Insert T-adapter.
and standard value 4) Connect connector.
when normal 5 Defective VHMS controller 5) Start engine.
Between HM-CN1 (2) HM-CN2A (12) Voltage 20 30 V
Between HM-CN2A (7) 20 C Voltage Approx. 0.9 1.2V
(12) 500 C Voltage Approx. 2.6 3.5 V
HD465-7, HD605-7 20-1015

(10)
TROUBLESHOOTING [DGT4KB]
[DGT4KB] (OR VHMS_LED DISPLAYS [n311])

SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN NO. 1, 2, 3
(FRONT) EXHAUST TEMPERATURE SENSOR SYSTEM (KB)
Action code Failure code Controller code Short circuit with power source (Hot short) in No. 1, 2, 3 (front)
Trouble
Not set DGT4KB Not set exhaust temperature sensor system (KB)
Contents of trouble Signal voltage of more than 4.9V detected from No. 1, 2, 3 (front) exhaust temperature sensor.
Problem that
No. 1, 2, 3 (front) exhaust temperature cannot be monitored with monitoring function
appears on machine
Related information

2) Replace No. 1, 2, 3 (front) exhaust temperature sensor
Defective No. 1, 2, 3 (front) Exhaust temperature sensor
defective
2) Disconnect connector HM-23A.
Defective No. 1, 2, 3 (front) 4) Connect connector.
amp
HM-23A Between (B) 20 C Voltage Approx. 0.9 1.2 V
2) Disconnect connectors HM-21A and HM-22A.
Probable cause Ground fault in wiring har-
and standard value 3 ness Resistance between HM-
when normal 22A (female) (1),
HM-22A (female) (1) HM- Min. 1 Mz
HM-21A (female) (1) chas-
21A (female) (1)
sis ground
2) Disconnect connectors HM-CN2A and HM-23A.
CN2 (female) (7),
HM-23A (female) (B) chas-
HM-23A (female) (B)
sis ground
5 Defective VHMS controller 5) Start engine.
Between HM-CN2A (7) 20 C Voltage Approx. 0.9 1.2 V
20-1016 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-1017

(2)
[DGT5KA] (OR VHMS_LED DISPLAYS [n322])

DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN NO. 4, 5, 6
(REAR) EXHAUST TEMPERATURE SENSOR SYSTEM (KA)
Action code Failure code Controller code Disconnection, short circuit with chassis ground in No. 4, 5, 6
Trouble
Not set DGT5KA Not set (rear) exhaust temperature sensor system (KA)
Contents of trouble Signal voltage of less than 0.3V detected from No. 4, 5, 6 (rear) exhaust temperature sensor.
Problem that
No. 4, 5, 6 (rear) exhaust temperature cannot be monitored with monitoring function
appears on machine
No. 4, 5, 6 (rear) exhaust temperature can be checked with monitoring function (code: 42601).
Related information

2) Replace No. 4, 5, 6 (rear) exhaust temperature sensor
Defective No. 4, 5, 6 (rear) Exhaust temperature sensor
defective
2) Disconnect connector HM-23B.
Defective No. 4, 5, 6 (rear) 4) Connect connector.
amp
HM-23B Between (B) 20 C Voltage Approx. 0.9 1.2 V
2) Disconnect connectors HM-CN1, HM-CN2A, HM-21B, HM-22B, and
HM-23B.
Probable cause 3) Connect T-adapter.
and standard value
Wiring harness between HM-CN1 (female) (2)
when normal Disconnection in wiring Resistance Max. 1 z
harness HM-23B (female) (A)
3
(disconnection, defective Wiring harness between HM-CN2A (female)
(5) HM-23B (female) (B)
Wiring harness between HM-22B (female) (1)
Resistance Max. 1 z
HM-21B (female) (1)
Wiring harness between HM-22B (female) (2)
Resistance Max. 1 z
HM-21B (female) (2)
2) Disconnect connectors HM-CN1, HM-CN2A, HM-21B, HM-22B, and
HM-23B.
Ground fault in wiring har- CN1 (female) (2), HM-23B
4 HM-CN1 (female) (2) Min. 1 Mz
ness (female) (A) chassis
HM-23B (female) (A)
ground
CN2A (female) (5), HM-23B
HM-23B (female) (B)
ground
20-1018 HD465-7, HD605-7

(10)

Probable cause 3) Insert T-adapter.
and standard value 4) Connect connector.
when normal 5 Defective VHMS controller 5) Start engine.
HD465-7, HD605-7 20-1019

(10)
[DGT5KB] (OR VHMS_LED DISPLAYS [n321])

SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN NO. 4, 5, 6
(REAR) EXHAUST TEMPERATURE SENSOR SYSTEM (KB)
Action code Failure code Controller code Short circuit with power source (Hot short) in No. 4, 5, 6 (rear) ex-
Trouble
Not set DGT5KB Not set haust temperature sensor system (KB)
Contents of trouble Signal voltage of more than 4.9V detected from No. 4, 5, 6 (rear) exhaust temperature sensor.
Problem that
No. 4, 5, 6 (rear) exhaust temperature cannot be monitored with monitoring function.
appears on machine
Related information

2) Replace No. 4, 5, 6 (rear) exhaust temperature sensor
Defective No. 4, 5, 6 (rear) Exhaust temperature sensor
defective
2) Disconnect connector HM-23B.
Defective No. 4, 5, 6 (rear) 4) Connect connector.
amp
HM-23B Between (B) 20 C Voltage Approx. 0.9 1.2 V
2) Disconnect connectors HM-21B and HM-22B.
Probable cause Ground fault in wiring har-
and standard value 3 ness Resistance between
when normal HM-22B (female) (1),
HM-22B (female) (1) HM- Min. 1 Mz
HM-21B (female) (1)
21B (female) (1)
chassis ground
2) Disconnect connectors HM-CN2A and HM-23B.
Resistance between
HM-CN2 (female) (5),
HM-23B (female) (B)
HM-23B (female) (B)
chassis ground
20-1020 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-1021

(2)
TROUBLESHOOTING [DHE5KB]
[DHE5KB] (OR VHMS_LED DISPLAYS [n332])

DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN ENGINE
BLOW-BY PRESSURE SENSOR SYSTEM (KA)
Action code Failure code Controller code Disconnection, short circuit with chassis ground in engine blow-
Trouble
Not set DHE5KB Not set by pressure sensor system (KA)
Contents of trouble Signal voltage of blow-by pressure sensor has dropped below 0.1V.
Problem that
Blow-by pressure cannot be monitored with monitoring function.
appears on machine
Blow-by pressure can be checked with monitoring function (code: 42800).
Related information

Defective engine blow-by 4) Connect connector.
1
pressure sensor 5) Turn starting switch ON.
Between HM-12 (B) (A) Voltage 4.5 5.5V
Between HM-12 (C) (A) Voltage 0.3 0.7V
2) Disconnect connectors HM-CN1, HM-CN2A, and HM-12.
2 ness (disconnection, defec- Wiring harness between HM-CN1 (female)
Resistance Max. 1 z
tive contact) (4),(5) HM-12 (female) (B)
Resistance Max. 1 z
(18) HM-12 (female) (C)
Probable cause
and standard value 2) Disconnect connectors HM-CN1, HM-CN2A, and HM-12.
when normal
CN1 (female) (4),(5), HM-12
Ground fault in wiring har- HM-CN1 (female) (4),(5) Min. 1 Mz
3 (female) (B) chassis
ness HM-12 (female) (B)
ground
(female) (C) - chassis
HM-12 (female) (C)
ground
4 Defective VHMS controller
5) Start engine.
Between HM-CN1 (5) HM-CN2A (12) Voltage 4.5 5.5V
Between HM-CN2A (18) (12) Voltage 0.3 0.7V
20-1022 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DHE5KY]
[DHE5KY] (OR VHMS_LED DISPLAYS [n331]) SHORT CIRCUIT WITH POWER

SOURCE (HOT SHORT) IN ENGINE BLOW-BY PRESSURE SENSOR SYS-
TEM (KY)
Action code Failure code Controller code Short circuit with power source (Hot short) in engine blow-by
Trouble
Not set DHE5KY Not set pressure sensor system (KY)
Contents of trouble Signal voltage of blow-by pressure sensor has risen above 4.7V.
Problem that
Blow-by pressure cannot be monitored with monitoring function.
appears on machine
Related information

Defective engine blow-by 4) Connect connector.
1
pressure sensor 5) Turn starting switch ON.
Between HM-12 (B) (A) Voltage 4.5 5.5 V
Between HM-12 (C) (A) Voltage 0.3 0.7 V
Probable cause
and standard value
when normal
HM-CN2A (female) (18) (female)(18), HM-12 (fe- Max. 1 V
HM-12 (female) (C) male) (C) chassis ground
Between HM-CN1 (5) HMCN2A (12) Voltage 4.5 5.5 V
Between HM-CN2A (18) (12) Voltage 0.3 0.7 V
HD465-7, HD605-7 20-1023

(10)
TROUBLESHOOTING [DhP4KX]
[DhP4KX] SUSPENSION PRESSURE SENSOR (FRONT RIGHT): OUT OF INPUT SIG-

NAL RANGE (KX)
Action code Failure code Controller code Suspension pressure sensor (Front right): Out of input signal
Trouble
E01 DhP4KX PLM range (KX)
The voltage of the signal circuit of the suspension pressure sensor (Front right) is below 0.3 V or above
Contents of trouble
4.9 V.
Problem that
The payload is not indicated and saved correctly.
appears on machine
The suspension pressure (Front right) signal can be checked with the monitoring function (Code:
Related information 32804).
This failure occurs only when the built-in PLM function is installed.

2) Disconnect connectors HM-CN1, HM-CN2B, and SUFR.
Disconnection in wiring har- Wiring harness between HM-CN2B (female) Resistance Max. 1 z
1 ness (Disconnection or de- (1) SUFR (female) (C)
fective contact) Wiring harness between HM-CN1 (female) (2)
Resistance Max. 1 z
SUFR (female) (B)
Wiring harness between HM-CN2B (female)
Resistance Max. 1 z
(9) SUFR (female) (A)
2) Disconnect connectors HM-CN1, HM-CN2B, and SUFR.
CN2B (female) (1), SUFR
Ground fault in wiring har- HM-CN2B (female) (1) Min. 1 M z
2 (female) (C) chassis
ness SUFR (female) (C)
ground
CN1 (female) (2), SUFR
HM-CN1 (female) (2) Min. 1 M z
Probable cause SUFR (female) (B)
ground
and standard value
when normal 1) Turn starting switch OFF.
2) Disconnect connectors HM-CN2B and SUFR.
Wiring harness between Voltage between HM-CN2B
HM-CN2B (female) (1) (female) (1), SUFR (female) Max. 1 V
3) Insert connect T-adapter.
Defective suspension pres- 4) Connect connector.
4
sure sensor (Front right) 5) Turn starting switch ON.
2) Disconnect connectors HM-CN1 and HM-CN2B.
Defective VHMS & PLM 4) Connect connector.
5
controller 5) Turn starting switch ON.
Between HM-CN1 (2) HM-CN2B (9) Voltage 20 30 V
Between HM-CN2B (1) (9) Voltage 1.0 4.6 V
20-1023-1 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-1023-2

(5)
[DhP5KX] SUSPENSION PRESSURE SENSOR (FRONT LEFT): OUT OF INPUT SIG-

NAL RANGE (KX)
Action code Failure code Controller code Suspension pressure sensor (Front left): Out of input signal
Trouble
The voltage of the signal circuit of the suspension pressure sensor (Front left) is below 0.3 V or above
Contents of trouble
4.9 V.
Problem that
appears on machine
The suspension pressure (Front left) signal can be checked with the monitoring function (Code:

2) Disconnect connectors HM-CN1, HM-CN2B, and SUFL.
1 ness (Disconnection or de- (2) SUFL (female) (C)
Resistance Max. 1 z
SUFL (female) (B)
Resistance Max. 1 z
(9) SUFL (female) (A)
2) Disconnect connectors HM-CN1, HM-CN2B, and SUFL.
Ground fault in wiring har- CN2B (female) (2), SUFL
2 HM-CN2B (female) (2) Min. 1 M z
ness (female) (C) chassis
SUFL (female) (C)
ground
HM-CN1 (female) (2) CN1 (female) (2), SUFL (fe- Min. 1 M z
Probable cause SUFL (female) (B) male) (B) chassis ground
when normal 2) Disconnect connectors HM-CN2B and SUFL.
HM-CN2B (female) (2) (female) (2), SUFL (female) Max. 1 V
4
sure sensor (Front left) 5) Turn starting switch ON.
5
20-1023-3 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-1023-4

(5)
[DhP6KX] SUSPENSION PRESSURE SENSOR (REAR RIGHT): OUT OF INPUT SIG-

NAL RANGE (KX)
Action code Failure code Controller code Suspension pressure sensor (Rear right): Out of input signal
Trouble
The voltage of the signal circuit of the suspension pressure sensor (Rear right) is below 0.3 V or above
Contents of trouble
4.9 V.
Problem that
appears on machine
The suspension pressure (Rear left) signal can be checked with the monitoring function (Code: 32806).
Related information

2) Disconnect connectors HM-CN1, HM-CN2B, and SURR.
1 ness (Disconnection or de- (7) SURR (female) (C)
Resistance Max. 1 z
SURR (female) (B)
Resistance Max. 1 z
(9) SURR (female) (A)
2) Disconnect connectors HM-CN1, HM-CN2B, and SURR.
CN2B (female) (7), SURR
Ground fault in wiring har- HM-CN2B (female) (7) Min. 1 M z
2 (female) (C) chassis
ness SURR (female) (C)
ground
CN1 (female) (7), SURR
HM-CN1 (female) (2) Min. 1 M z
Probable cause SURR (female) (B)
ground
and standard value
when normal 1) Turn starting switch OFF.
2) Disconnect connectors HM-CN2B and SURR.
HM-CN2B (female) (7) (female) (7), SURR (female) Max. 1 V
SURR (female) (C) (C) chassis ground
2) Disconnect connector SURR.
4
sure sensor (Rear right) 5) Turn starting switch ON.
Between SURR (B) (A) Voltage 20 30 V
Between SURR (C) (A) Voltage 1.0 4.6 V
5
20-1023-5 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-1023-6

(5)
[DhP7KX] SUSPENSION PRESSURE SENSOR (REAR LEFT): OUT OF INPUT SIGNAL

RANGE (KX)
Action code Failure code Controller code Suspension pressure sensor (Rear right): Out of input signal
Trouble
The voltage of the signal circuit of the suspension pressure sensor (Rear left) is below 0.3 V or above
Contents of trouble
4.9 V.
Problem that
appears on machine
The suspension pressure (Rear left) signal can be checked with the monitoring function (Code: 32807).
Related information

2) Disconnect connectors HM-CN1, HM-CN2B, and SURL.
1 ness (Disconnection or de- (8) SURL (female) (C)
Resistance Max. 1 z
SURL (female) (B)
Resistance Max. 1 z
(9) SURL (female) (A)
2) Disconnect connectors HM-CN1, HM-CN2B, and SURL.
Ground fault in wiring har- CN2B (female) (8), SURL
2 HM-CN2B (female) (8) Min. 1 M z
ness (female) (C) chassis
SURL (female) (C)
ground
HM-CN1 (female) (2) CN1 (female) (2), SURL (fe- Min. 1 M z
Probable cause SURL (female) (B) male) (B) chassis ground
when normal 2) Disconnect connectors HM-CN2B and SURL.
HM-CN2B (female) (8) (female) (8), SURL (female) Max. 1 V
SURL (female) (C) (C) chassis ground
2) Disconnect connector SURL.
4
sure sensor (Rear left) 5) Turn starting switch ON.
Between SURL (B) (A) Voltage 20 30 V
Between SURL (C) (A) Voltage 1.0 4.6 V
5
20-1023-7 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-1023-8

(5)
TROUBLESHOOTING [DKH1KX]
[DKH1KX] PITCH ANGLE SENSOR: OUT OF INPUT SIGNAL RANGE (KX)

Trouble Pitch angle sensor: Out of input signal range (KX)
E01 DKH1KX PLM
Contents of trouble The voltage of the signal circuit of the pitch angle sensor is below 0.3 V or above 4.9 V.
Problem that
appears on machine
The pitch angle sensor signal [Angle (rad.)] can be checked with the monitoring function (Code:

2) Disconnect connectors HM-CN1, HM-CN2B, and PM3.
1 ness (Disconnection or de- (3) PM3 (female) (B)
Resistance Max. 1 z
PM3 (female) (C)
Resistance Max. 1 z
(9) PM3 (female) (A)
2) Disconnect connectors BRC3B and PM3.
2 HM-CN2B (female) (3) CN2B (female) (3), PM3 (fe- Min. 1 M z
ness
PM3 (female) (B) male) (B) chassis ground
HM-CN1 (female) (2) CN1 (female) (2), PM3 (fe- Min. 1 M z
PM3 (female) (C) male) (C) chassis ground
Probable cause
when normal 2) Disconnect connectors BRC3B and PM3.
HM-CN2B (female) (3) (female) (3), MP3 (female) Max. 1 V
PM3 (female) (B) (B) chassis ground
2) Disconnect connectors PM3.
4 Defective pitch angle sensor 4) Connect connector.
Between PM3 (C) (A) Voltage 20 30 V
Between PM3 (B) (A) Voltage 1.0 4.6 V
2) Disconnect connectors HM-CN1 and HM-CN2B
5
20-1023-9 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DKH1KX]
HD465-7, HD605-7 20-1023-10

(6)
TROUBLESHOOTING [F@BBZL]
[F@BBZL] (OR VHMS_LED DISPLAYS [n338])

ENGINE BLOW-BY PRESSURE IS HIGH: (ZL)

Trouble Engine blow-by pressure is high: (ZL)
Not set F@BBZL Not set
Contents of trouble Blow-by threshold value exceeds 8.83 kPa {900 mmH2O}.
Problem that
appears on machine
Related information
If failure codes [DHE5KA] or [DHE5KY] are displayed, carry out troubleshooting first for the applicable
code.

Abnormal rise in blow-by
Probable cause 1 Inspect engine and repair if any abnormality is found
pressure
and standard value
when normal Defective orifice inside
2 Inspect orifice inside breather and repair if any abnormality is found
breather
3 Defective VHMS controller If Items 1 and 2 are normal, defective VHMS controlle
20-1024 HD465-7, HD605-7

(10)
TROUBLESHOOTING [F@BYNR]
[F@BYNR] (OR VHMS_LED DISPLAYS [n362])

NO. 1, 2, 3 (FRONT) EXHAUST TEMPERATURE IS HIGH (2):(NR)

Trouble No. 1, 2, 3 (front) exhaust temperature is high (2):(NR)
Not set F@BYNR Not set
Signal circuit of No. 1, 2, 3 (front) exhaust temperature sensors has detected more than exhaust tem-
Contents of trouble perature limit line 2 for more than 10 seconds. (Exhaust temperature limit line 2: Straight line between
750 C at more than rated output speed and 800 C at less than max. torque speed)
Problem that
appears on machine
No. 1, 2, 3 (front) exhaust temperature can be checked with monitoring function (code: 42600)
Related information
If failure codes [DGT4KA] or [DGT4KB] are displayed, carry out troubleshooting first for the applicable
code.

Abnormal rise in exhaust
temperature for No. 1, 2, 3
1 Inspect engine and repair if any abnormality is found
(front)
(When system is normal)
and standard value 2) Disconnect connectors HM-CN1 and HM-CN2A.
when normal 3) Insert T-adapter.
HD465-7, HD605-7 20-1025

(10)
TROUBLESHOOTING [F@BYNS]
[F@BYNS] (OR VHMS_LED DISPLAYS [n361])

NO. 1, 2, 3 (FRONT) EXHAUST TEMPERATURE IS HIGH (1):(NS)

Trouble No. 1, 2, 3 (front) exhaust temperature is high (1):(NS)
Not set F@BYNS Not set
Signal circuit of No. 1, 2, 3 (front) exhaust temperature sensors has detected more than exhaust tem-
Contents of trouble perature limit line 1 for more than 1 second. (Exhaust temperature limit line 1: Straight line between
Problem that
appears on machine
Related information
code.

(front)
20-1026 HD465-7, HD605-7

(10)
TROUBLESHOOTING [F@BZNR]
[F@BZNR] (OR VHMS_LED DISPLAYS [n372])

NO. 4, 5, 6 (REAR) EXHAUST TEMPERATURE IS HIGH (2):(NR)

Trouble No. 4, 5, 6 (rear) exhaust temperature is high (2):(NR)
Not set F@BZNR Not set
Signal circuit of No. 4, 5, 6 (rear) exhaust temperature sensors has detected more than exhaust tem-
Contents of trouble perature limit line 2 for more than 10 seconds. (Exhaust temperature limit line 2: Straight line between
Problem that
appears on machine
Related information
code.

(rear)
HD465-7, HD605-7 20-1027

(10)
TROUBLESHOOTING [F@BZNS]
[F@BZNS] (OR VHMS_LED DISPLAYS [n371])

NO. 4, 5, 6 (REAR) EXHAUST TEMPERATURE IS HIGH (1):(NS)

Trouble No. 4, 5, 6 (rear) exhaust temperature is high (1):(NS)
Not set F@BZNS Not set
Signal circuit of No. 4, 5, 6 (rear) exhaust temperature sensors has detected more than exhaust tem-
Contents of trouble perature limit line 1 for more than 1 second. (Exhaust temperature limit line 1: Straight line between
Problem that
appears on machine
Related information
code.

(rear)
20-1028 HD465-7, HD605-7

(10)
TROUBLESHOOTING VHMS-1
VHMS-1 ABNORMALITY IN SATELLITE DATA COMMUNICATION

a) Satellite communication data are not transmitted
Action code Failure code Controller code Abnormality in satellite data communication
Trouble
Not set Not set Not set a) Satellite communication data are not transmitted
Contents of trouble Satellite communication data are not transmitted.
Problem that
Satellite communication data are not transmitted.
appears on machine
Related information

Machine is in tunnel or build- Not defective.
1
ing aMove the machine outdoors.
Machine is behind building Not defective.
2 or mountain and only a part aMove the machine to a place from where you can look out over the
of heaven is seen from it heavens.
Abnormality in communica- Check communication antenna. If it is broken or removed, repair or
3
tion antenna replace it.
Entry of foreign matter in
4 communication antenna Check inside of communication antenna and remove foreign matter.
connector
Abnormality in communica- Check communication antenna. If it is broken (or disconnected), re-
5
tion antenna cable pair or replace it.
2) Disconnect connectors HM-CN1, HM-CN2B, HM-CN4B, ORB-A,
and ORB-B.
Wiring harness between ORB-B (female) (1)
Resistance Max. 1 z
HM-CN4B (female) (4)
Wiring harness between ORB-B (female) (2)
Probable cause Disconnection in wiring har- HM-CN4B (female) (10) Resistance Max. 1 z
and standard value 6 ness (Disconnection or de-
when normal Wiring harness between ORB-B (female) (3)
fective contact) Resistance Max. 1 z
HM-CN4B (female) (3)
Wiring harness between ORB-A (female) (7),
Resistance Max. 1 z
(8) HM-CN1 (female) (6), (7)
Wiring harness between ORB-A (female) (10),
Resistance Max. 1 z
(11) HM-CN1 (female) (19), (20)
Wiring harness between ORB-A (female) (2)
Resistance Max. 1 z
HM-CN2 (female) (17)
and ORB-B.
Wiring harness between Resistance between ORB-B
ORB-B (female) (1) HM- (female) (1), HM-CN4B (fe- Min. 1M z
Ground fault or short circuit CN4B (female) (4) male) (4) chassis ground
7
in wiring harness
CN4B (female) (10) male) (10) chassis ground
HD465-7, HD605-7 20-1029

(10)

Resistance between ORB-A
(female) (7), (8), HM-CN1
ORB-A (female) (7), (8) Min. 1M z
(female) (6), (7) chassis
HM-CN1 (female) (6), (7)
ground
(female) (10), (11), HM-CN1
ORB-A (female) (10), (11) Min. 1M z
(female) (19), (20) chassis
HM-CN1 (female) (19), (20)
ground
Wiring harness between Resistance between ORB-A
ORB-A (female) (2) HM- (female) (2), HM-CN2A (fe- Min. 1M z
CN2A (female) (17) male) (17) chassis ground
ORB-B (female) (1) HM- (female) (1) HM-CN4B (fe-
CN4B (female) (4) and be- male) (4) and between ORB- Min. 1M z
tween ORB-B (female) (2) B (female) (2) HM-CN4B
HM-CN4B (female) (10) (female) (10)
7
Ground fault or short circuit CN4B (female) (4) and be- male) (4) and between ORB- Min. 1M z
in wiring harness tween ORB-B (female) (3) B (female) (3) HM-CN4B
Probable cause HM-CN4B (female) (3) (female) (3)
and standard value
when normal
CN4B (female) (10) and be- male) (10) and between Min. 1M z
tween ORB-B (female) (3) ORB-B (female) (3) HM-
HM-CN4B (female) (3) CN4B (female) (3)
Wiring harness between Resistance between ORB-A
ORB-A (female) (7), (8) (female) (7), (8) HM-CN1
HM-CN1 (female) (6), (7) (female) (6), (7) and be-
Min. 1M z
and between ORB-A (fe- tween ORB-A (female) (10),
male) (10), (11) HM-CN1 (11) HM-CN1 (female)
(female) (19), (20) (19), (20)
ORB-A (female) (2) HM-
(female) (2) HM-CN2A (fe-
CN2A (female) (17) and be-
male) (17) and between Min. 1M z
tween ORB-A (female) (10),
ORB-A (female) (10), (11)
(11) HM-CN1 (female)
HM-CN1 (female) (19), (20)
(19), (20)
and ORB-B.
20-1030 HD465-7, HD605-7

(10)

Wiring harness between Voltage between ORB-B (fe-
ORB-B (female) (1) HM- male) (1), HM-CN4B (fe- Max. 1 V
Wiring harness between Voltage between ORB-B
ORB-B (female) (2) HM- (female) (2), HM-CN4B (fe- Max. 1 V
Wiring harness between Voltage between ORB-B (fe-
ORB-B (female) (3) HM- male) (3), HM-CN4B (fe- Max. 1 V
Wiring harness between Voltage between ORB-A (fe-
ORB-A (female) (2) HM- male) (2), HM-CN2A (fe- Max. 1 V
CN2A (female) (17) male) (17) chassis ground
Probable cause 1) Turn starting switch ON.
and standard value About 3 minutes after the VHMS controller is turned ON, judge by
when normal the state of the decimal point of the VHMS controller LED (7 seg-
ments on the right side).
VHMS controller cannot communicate with
Decimal point goes off ORBCOMM controller (Abnormality in ORB-
COMM controller).
Defective ORBCOMM con- Communication with VHMS is normal.
9
troller Decimal point lights up ORBCOMM controller does not have data to
transmit.
Communication with VHMS is normal.
Decimal point flashes
ORBCOMM controller has data to transmit
quickly
and has captured satellite (is transmitting).
Communication with VHMS is normal.
Decimal point flashes
ORBCOMM controller has data to transmit
slowly
but has not captured satellite.
HD465-7, HD605-7 20-1031

(10)
b) Abnormality in downloading into PC or setting of PC
Action code Failure code Controller code Abnormality in satellite data communication
Trouble
Not set Not set Not set b) Abnormality in downloading into PC or setting of PC
Contents of trouble PC cannot download or cannot be set.
Problem that
PC cannot download or cannot be set.
appears on machine
Related information

2) Disconnect connectors HM-CN4A and VHMS.
ness (Disconnection or de- Wiring harness between HM-CN4A (female)
Resistance Max. 1 z
1 fective contact) (9) VHMS (female) (B)
aWiring harness for down- Wiring harness between HM-CN4A (female)
loading in cab Resistance Max. 1 z
(10) VHMS (female) (C)
Resistance Max. 1 z
(11) VHMS (female) (D)
2) Disconnect connectors HM-CN4A and VHMS.
HM-CN4A (female) (9) CN4A (female) (9), VHMS
Min. 1M z
VHMS (female) (B) (female) (B) chassis
ground
Probable cause HM-CN4A (female) (10) CN4A (female) (10), VHMS
Min. 1M z
and standard value VHMS (female) (C) (female) (C) chassis
when normal ground
HM-CN4A (female) (11) CN4A (female) (11), VHMS
Min. 1M z
Ground fault or short circuit VHMS (female) (D) (female) (D) chassis
in wiring harness ground
2
aWiring harness for down- Wiring harness between Resistance between HM-
loading inside cab HM-CN4A (female) (9) CN4A (female) (9) VHMS
VHMS (female) (B) and be- (female) (B) and between Min. 1M z
tween HM-CN4A (female) HM-CN4A (female) (10)
(10) VHMS (female) (C) VHMS (female) (C)
HM-CN4A (female) (9) CN4A (female) (9) VHMS
VHMS (female) (B) and be- (female) (B) and between Min. 1M z
(11) VHMS (female) (D) VHMS (female) (D)
HM-CN4A (female) (10) CN4A (female) (10) VHMS
VHMS (female) (C) and be- (female) (C) and between Min. 1M z
(11) VHMS (female) (D) VHMS (female) (D)
20-1032 HD465-7, HD605-7

(10)

2) Disconnect connectors VHMS and VDL.
ness (Disconnection or de- Wiring harness between VHMS (male) (B)
Resistance Max. 1 z
3 fective contact) VDL (female) (B)
aWiring harness for down- Wiring harness between VHMS (male) (C)
loading inside cab Resistance Max. 1 z
VDL (female) (C)
Wiring harness between VHMS (male) (D)
Resistance Max. 1 z
VDL (female) (D)
2) Disconnect connectors VHMS and VDL.
Wiring harness between Resistance between VHMS
VHMS (male) (B) VDL (fe- (male) (B) VDL (female) Min. 1M z
male) (B) (B) chassis ground
Probable cause
VHMS (male) (C) VDL (fe- (male) (C) VDL (female) Min. 1M z
and standard value
male) (C) (C) chassis ground
when normal
VHMS (male) (D) VDL (fe- (male) (D) VDL (female) Min. 1M z
male) (D) (D) chassis ground
Ground fault or short circuit
in wiring harness Wiring harness between Resistance between VHMS
4
aWiring harness for down- VHMS (male) (B) VDL (fe- (male) (B) VDL (female)
loading outside cab male) (B) and between (B) and between VHMS Min. 1M z
VHMS (male) (C) VDL (fe- (male) (C) VDL (female)
male) (C) (C)
Wiring harness between Resistance betweenVHMS
VHMS (male) (B) VDL (fe- (male) (B) VDL (female)
male) (B) and between (B) and between VHMS Min. 1M z
VHMS (female) (D) VDL (male) (D) VDL (female)
(male) (D) (D)
VHMS (male) (C) VDL (fe- (male) (C) VDL (female)
male) (C) and between (C) and between VHMS Min. 1M z
VHMS (male) (D) VDL (fe- (male) (D) VDL (female)
male) (D) (D)
HD465-7, HD605-7 20-1033

(10)
VHMS-2 ABNORMALITY IN SAVING DATA IN VHMS CONTROLLER

(DATA ARE NOT SAVED)
Action code Failure code Controller code Abnormality in saving data in VHMS controller
Trouble (Data are not saved)
Not set Not set Not set a LED of VHMS counts up and operates normally
Data are not saved in the VHMS controller.
Contents of trouble
aPower is kept turned off.
Problem that
None in particular.
appears on machine
If fuse BT-2 (29) is broken, check the wiring harness between fuse and HM-CN1 (6), (7) for grounding
Related information
fault.

2) Disconnect connector HM-CN1 and fuse terminal BT-2 (29).
Wiring harness between HM-CN1 (female) (6),
Probable cause Resistance Max. 1 z
(7) fuse terminal BT-2 (29)
and standard value Disconnection in wiring har-
when normal 1 ness (Disconnection or de- *1) After the starting switch is turned to the OFF position, the LED of
fective contact) the VHMS displays SH (Processing time of memory), and then the
all operation is finished (the power for the VHMS is turned OFF), if
the all system is normal.
*2) If the power for the VHMS is turned OFF immediately after the
starting switch is turned to the OFF position, the power is not ap-
plied constantly.
20-1034 HD465-7, HD605-7

(10)
HD465-7, HD605-7 20-1035

(5)
VHMS-3 ENGINE BLOW-BY PRESSURE INDICATED BY MONITOR IS LOW

(WHEN BLOW-BY PRESSURE MEASURED WITH MEASURING INSTRUMENT
IS NORMAL)
Action code Failure code Controller code Engine blow-by pressure indicated by monitor is low
Trouble (When blow-by pressure measured with measuring instrument
Not set Not set Not set is normal)
Contents of trouble The engine blow-by pressure indicated by the monitor is low.
Problem that The engine blow-by pressure indicated by the monitor is low.
appears on machine (The blow-by pressure measured with a measuring instrument is normal.)
The blow-by pressure can be checked with the monitoring function (Code: 42800).
Related information
If failure code "DHE5KA" is indicated, carry out the troubleshooting for it.
Probable cause Cause Standard value in normal state/Remarks on troubleshooting

and standard value 1 Defective orifice in breather Check the orifice in the breather and repair it, if abnormal.
when normal 2 Defective VHMS controller If the result of 1 above is normal, the VHMS controller is defective.
20-1036 HD465-7, HD605-7

(10)
TROUBLESHOOTING OF ASR
CONTROLLER SYSTEM
(ASR MODE)
Electrical system diagram related ASR control ........................................................................................ 20-1052

Information in troubleshooting table...................................................................................................... 20-1053
Phenomenon code table....................................................................................................................... 20-1054
[DDDAKA] ASR system switch system: Disconnection (KA).............................................................. 20-1055
[DDDAKB] ASR system switch system: Short circuit (KB) ................................................................. 20-1056
[DK30KX] Steering angle sensor: Out of input signal range (KX) .................................................... 20-1057
[DLF8KA] Wheel speed sensor (RR): Disconnection (KA) ............................................................... 20-1059
[DLF8LC] Wheel speed sensor (RR): *See separate list (LC) ......................................................... 20-1060
[DLF9KA] Wheel speed sensor (RL): Disconnection (KA) ................................................................ 20-1061
[DLF9LC] Wheel speed sensor (RL): *See separate list (LC)........................................................... 20-1062
[dLT3LC] Transmission output shaft speed sensor: *See separate list (LC) ................................... 20-1063
[DWNBK4] Shut-off solenoid valve: Uncontrollable (K4) .................................................................... 20-1065
[DWNBKA] Shut-off solenoid valve: Disconnection (KA) .................................................................... 20-1067
[DWNBKB] Shut-off solenoid valve: Short circuit (KB) ....................................................................... 20-1068
[DWNBKY] Shut-off solenoid valve: Short circuit with power source (Hot short) (KY) ........................ 20-1069
[DWNBMA] Shut-off solenoid valve: Malfunction (MA) ........................................................................ 20-1070
[DX17K4] ASR proportional solenoid pressure reducing valve (Right): Uncontrollable (K4) ............ 20-1071
[DX17KA] ASR proportional solenoid pressure reducing valve (Right): Disconnection (KA) ............ 20-1073
[DX17KB] ASR proportional solenoid pressure reducing valve (Right): Short circuit (KB)................ 20-1074
[DX17KY] ASR proportional solenoid pressure reducing valve (Right): Short circuit with
power source (Hot short) (KY).......................................................................................... 20-1075
[DX17MA] ASR proportional solenoid pressure reducing valve (Right): Malfunction (MA)................ 20-1076
[DX18K4] ASR proportional solenoid pressure reducing valve (Left): Uncontrollable (K4) .............. 20-1077
[DX18KA] ASR proportional solenoid pressure reducing valve (Left): Disconnection (KA) .............. 20-1079
[DX18KB] ASR proportional solenoid pressure reducing valve (Left): Short circuit (KB) .................. 20-1080
[DX18KY] ASR proportional solenoid pressure reducing valve (Left): Short circuit with
power source (Hot short) (KY).......................................................................................... 20-1081
[DX18MA] ASR proportional solenoid pressure reducing valve (Left): Malfunction (MA) .................. 20-1082
HD465-7, HD605-7 20-1051

(10)
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED ASR CONTROL
ELECTRICAL SYSTEM DIAGRAM RELATED ASR CONTROL
20-1052 HD465-7, HD605-7

(5)

panel panel panel
Contents of trouble Condition at the time when the monitor panel or controller detects the trouble
The action taken by the monitor panel or controller to protect the system or devices when the monitor-
panel or controller detects the trouble
Problem that The problem that appears on the machine as a result of the action taken by the monitor panel or controller
appears on machine (shown above)
Related information Information related to the detected trouble or troubleshooting

Remarks on judgment
1
Disconnection
Ground fault
Short circuit
Possible causes 3 Possible causes of trouble <Precautions for troubleshooting>

and standard value (Given numbers are refer- 1) Method of indicating connector No. and handling of T-
in normal state ence numbers, which do not adapter
indicate priority) Insert or connect T-adapter as explained below for trouble-
shooting, unless otherwise specified.
4
side.
If connector No. has marks of "male" and "female", disconnect
Connect positive (+) lead and negative () lead of tester as
explained below for troubleshooting, unless otherwise
specified.
5 Connect positive (+) lead to pin No. or harness entered on front
side.
side.
HD465-7, HD605-7 20-1053

(10)
This a circuit diagram of the part related to the failure.

Connector No.: Shows the "Type Number of pin" and " Color".
Arrow ( ): Roughly shows the location on the machine.





MW Sliding
NS Overheat
20-1054 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DDDAKA]
[DDDAKA] ASR SYSTEM SWITCH SYSTEM: DISCONNECTION (KA)

Trouble ASR system switch system: Disconnection (KA)
E01 DDDAKA BK
Contents of trouble The ASR system switch ON input and system switch OFF input are turned OFF.
Action of controller Resets the ASR control.
Problem that The machine is not affected badly.
appears on machine The ASR system cannot be controlled.
Related information The state of the ASR switch can be checked with the monitoring function (Code: 37900).

2) Disconnect connectors ASR and DPC2B.
Disconnection in wiring Wiring harness between DPC2B (female) (3)
Resistance Max. 1 z
harness ASR (female) (3)
1
(Disconnection or defective 1) Turn starting switch OFF.
contact) 2) Disconnect connectors ASR and DPC2B.
Resistance Max. 1 z
ASR (female) (3)
2) Replace ASR system switch with normal one.
Possible causes
and standard value 3) Turn starting switch ON.
Defective ASR system
in normal state 2 System switch is
switch When ASR system switch is Yes
normal
replaced with normal one, does
condition become normal? System switch is
No
defective
3 Defective machine monitor
Between DPC2B (3) ASR system switch ON Voltage 20 30 V
chassis ground ASR system switch OFF Voltage Max. 1 V
Between DPC2B (9) ASR system switch ON Voltage Max. 1 V
chassis ground ASR system switch OFF Voltage 20 30 V
HD465-7, HD605-7 20-1055

(10)
TROUBLESHOOTING [DDDAKB]
[DDDAKB] ASR SYSTEM SWITCH SYSTEM: SHORT CIRCUIT (KB)

Trouble ASR system switch system: Short circuit (KB)
E01 DDDAKB BK
Contents of trouble The ASR system switch ON input and system switch OFF input are turned ON.
Related information The state of the ASR switch can be checked with the monitoring function (Code: 37900).

2) Disconnect connectors ASR and DPC2B.
1 Hot short in wiring harness DPC2B (female) (3) ASR male) (3), ASR (female) (3) Max. 1 V
DPC2B (female) (9) ASR male) (9), ASR (female) (2) Max. 1 V
2) Replace ASR system switch with normal one.
Possible causes
Defective ASR system 3) Turn starting switch ON.
and standard value
in normal state 2 switch System switch is
When ASR system switch is re- Yes
normal
placed with normal one, does con-
dition become normal? System switch is
No
defective
Between DPC2B (3) ASR system switch ON Voltage 20 30 V
chassis ground ASR system switch OFF Voltage Max. 1 V
Between DPC2B (9) ASR system switch ON Voltage Max. 1 V
chassis ground ASR system switch OFF Voltage 20 30 V
20-1056 HD465-7, HD605-7

(10)
[DK30KX] STEERING ANGLE SENSOR: OUT OF INPUT SIGNAL RANGE (KX)

Trouble Steering angle sensor: Out of input signal range (KX)
E01 DK30KX BK
Contents of trouble The voltage of the signal circuit of the steering angle sensor is below 0.5 V or above 4.7 V.
Action of controller Controls the ASR by setting the steering angle (turning angle) to 20 degrees.
Problem that
The machine is not affected badly.
appears on machine
Related information The steering angle can be checked with the monitoring function (Code: 35400).

2) Disconnect connectors BRC2, BRC3A, and ASR1.
Disconnection in wiring Wiring harness between BRC2 (female) (16)
1 ASR1 (female) (3)
ASR1 (female) (2)
Resistance Max. 1 z
ASR1 (female) (1)
Wiring harness between Resistance between BRC2
Ground fault in wiring har- BRC2 (female) (16) ASR1 (female) (16), ASR 1 (female) Min. 1 Mz
2
ness (female) (3) (3) chassis ground
BRC3A (female) (7) ASR1 (female) (7), ASR1 (female) Min. 1 Mz
Possible causes
and standard value
in normal state
3 Hot short in wiring harness Wiring harness between Voltage between BRC2
BRC2 (female) (16) ASR1 (female) (16), ASR1 (female) Max. 1 V
Wiring harness between Voltage between BRC3A
BRC3A (female) (7) ASR1 (female) (7), ASR1 (female) Max. 1 V
2) Disconnect connector RTL.
Defective steering angle 4) Connect connector.
4
sensor 5) Turn starting switch ON.
Between ASR1 (3) (1) Voltage 4.6 5.4 V
Between ASR1 (2) (1) Voltage 23V
2) Disconnect connectors BRC2 and RTL.
5 Defective retarder controller
Between BRC1 (16) BRC3A (16) Voltage 4.6 5.4 V
Between BRC3A (7) (16) Voltage 23V
HD465-7, HD605-7 20-1057

(10)
20-1058 HD465-7, HD605-7

(5)
[DLF8KA] WHEEL SPEED SENSOR (RR): DISCONNECTION (KA)

Trouble Wheel speed sensor (RR): Disconnection (KA)
E01 DLF8KA BK
Contents of trouble The signal circuit of the wheel speed sensor (RR) is disconnected and signals are not input.
Related information The wheel speed (RR) can be checked with the monitoring function (Code: 39701).

2) Disconnect connector WSRR.
Defective wheel speed
1
sensor (RR) Between WSRR (male) (1) (2) Resistance 950 1,450 z
Between WSRR (male) (1), (2) chassis
ground
Possible causes
2) Disconnect connectors BRC3A and WSRR.
and standard value Disconnection in wiring 3) Connect T-adapter.
in normal state harness
(Disconnection or defective WSRR (female) (1) Resistance Max. 1 z
contact)
Resistance Max. 1 z
WSRR (female) (2)
3 Defective retarder controller 3) Connect T-adapter.
HD465-7, HD605-7 20-1059

(10)
[DLF8LC] WHEEL SPEED SENSOR (RR): *SEE SEPARATE LIST (LC)

Trouble Wheel speed sensor (RR): *See separate list (LC)
E01 DLF8LC BK
The wheel speed (RR) calculated from the transmission output shaft speed sensor signal and wheel
Contents of trouble
(RL) speed sensor signal is different from the signal speed of the wheel (RR) speed sensor.
Related information The wheel speed (RR) can be checked with the monitoring function (Code: 39701).

2) Disconnect connector WSRR.
1
sensor (RR) Between WSRR (male) (1) (2) Resistance 950 1,450 z
Between WSRR (male) (1), (2) chassis
ground
2
Possible causes
and standard value BRC3A (female) (3) (female) (3), WSRR (female) Min. 1 Mz
in normal state WSRR (female) (1) (1) chassis ground
ness
BRC3A (female) (3) male) (3), WSRR (female) (1) Max. 1 V
WSRR (female) (1) chassis ground
20-1060 HD465-7, HD605-7

(10)
[DLF9KA] WHEEL SPEED SENSOR (RL): DISCONNECTION (KA)

Trouble Wheel speed sensor (RL): Disconnection (KA)
E01 DLF9KA BK
Contents of trouble The signal circuit of the wheel speed sensor (RL) is disconnected and signals are not input.
Related information The wheel speed (RL) can be checked with the monitoring function (Code: 39700).

2) Disconnect connector WSRL.
Defective wheel speed sen- 3) Connect T-adapter.
1
sor (RL) Between WSRL (male) (1) (2) Resistance 950 1,450 z
Between WSRL (male) (1), (2) chassis
ground
Possible causes
2) Disconnect connectors BRC3A and WSRL.
and standard value Disconnection in wiring 3) Connect T-adapter.
in normal state harness
WSRL (female) (1)
contact)
Resistance Max. 1 z
WSRL (female) (2)
HD465-7, HD605-7 20-1061

(10)
[DLF9LC] WHEEL SPEED SENSOR (RL): *SEE SEPARATE LIST (LC)

Trouble Wheel speed sensor (RL): *See separate list (LC)
E01 DLF9LC BK
The wheel speed (RL) calculated from the transmission output shaft speed sensor signal and wheel
Contents of trouble
(RR) speed sensor signal is different from the signal speed of the wheel (RL) speed sensor.
Related information The wheel speed (RL) can be checked with the monitoring function (Code: 39700).

2) Disconnect connector WSRL.
1
sensor (RL) Between WSRL (male) (1) (2) Resistance 950 1,450 z
Between WSRL (male) (1), (2) chassis
ground
2
Possible causes
and standard value BRC3A (female) (3) WSRL (female) (3), WSRL (female) Min. 1 Mz
in normal state (female) (1) (1) chassis ground
ness
Wiring harness between Voltage between BRC3A
BRC3A (female) (3) WSRL (female) (3), WSRL (female) Max. 1 V
20-1062 HD465-7, HD605-7

(10)
TROUBLESHOOTING [dLT3LC]
[dLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR:

*SEE SEPARATE LIST (LC)
Action code Failure code Controller code Transmission output shaft speed sensor: *See separate list (LC)
Trouble
E01 dLT3LC BK (ASR is set and ASR system switch is turned ON)
The travel speed calculated from the transmission output shaft speed sensor signal, wheel (RR) speed
Contents of trouble sensor signal, and wheel (RL) speed sensor signal is different from the signal speed of the wheel (RR)
speed sensor and wheel (RL) speed sensor.
The transmission output shaft speed can be checked with the monitoring function (Code: 31400).
Related information
The wheel speed can be checked with the monitoring function (Code: 39700, 39701).

Defective transmission 3) Connect T-adapter.
1
output shaft speed sensor
2) Disconnect connectors ATC3A, BRC3A, PM5, and CN5.
Ground fault in wiring har- Wiring harness between
2 Resistance between BRC3A
ness ATC3A (female) (3)
(female) (13), ATC3A (female)
BRC3A (female) (13) PM5 Min. 1 Mz
Possible causes (female) (7) CN5 (female) (3), PM5 (female) (7), CN5 (fe-
and standard value (1) male) (1) chassis ground
in normal state
2) Disconnect connectors BRC3A, ATC3A, PM5, and CN5.
Wiring harness between Voltage between ATC3A
ATC3A (female) (3) (female) (3), BRC3A (female)
BRC3A (female) (13) PM5 Max. 1 V
(female) (7) CN5 (female) (13), PM5 (female) (7), CN5
(1) (female) (1) chassis ground

Defective transmission con- 2) Disconnect connector BRC3A.
troller
HD465-7, HD605-7 20-1063

(10)
TROUBLESHOOTING [dLT3LC]
20-1064 HD465-7, HD605-7

(5)
TROUBLESHOOTING [DWNBK4]
[DWNBK4] SHUT-OFF SOLENOID VALVE: UNCONTROLLABLE (K4)

Trouble Shut-off solenoid valve: Uncontrollable (K4)
E01 DWNBK4 BK
Contents of trouble The shut-off solenoid valve does not return (does not move) or the pressure switch system is defective.
Related information

Defective shut-off solenoid Check the shut-off solenoid valve and repair or replace it, if it has
1
valve abnormality (mechanical failure).
2) Disconnect connector ASR7.
Defective shut-off solenoid 4) Connect connector.
2
valve oil pressure switch 5) Turn starting switch ON.
Between ASR7 (female) (1) Oil pressure ON Resistance Max. 1 z
(2) Oil pressure OFF Resistance Min. 1 Mz
2) Disconnect connectors BRC5B and ASR7.
Ground fault in wiring 4) Connect connector.
harness
Possible causes
and standard value Wiring harness between Resistance between BRC5B
in normal state BRC5B (female) (8) ASR7 (female) (8), ASR7 (female) Max. 1 z
Wiring harness between Voltage between BRC5B
BRC5B (female) (8) ASR7 (female) (8), ASR7 (female) Max. 1 V
2) Disconnect connectors BRC5B and BRC2.
Between BRC5B (8) BRC2 Oil pressure ON Voltage Max. 1 V
(21) Oil pressure OFF Voltage 20 30 V
HD465-7, HD605-7 20-1065

(10)
TROUBLESHOOTING [DWNBK4]
20-1066 HD465-7, HD605-7

(5)
TROUBLESHOOTING [DWNBKA]
[DWNBKA] SHUT-OFF SOLENOID VALVE: DISCONNECTION (KA)

Trouble Shut-off solenoid valve: Disconnection (KA)
E01 DWNBKA BK
Contents of trouble When the output to the shut-off solenoid valve circuit is turned ON, any current does not flow.
Related information

1
valve 5) Turn starting switch ON.
Between ASR2 (female) (1) (2) Resistance 10 30 z
Between ASR2 (1), (2) chassis ground Resistance Min. 1 Mz
Possible causes
and standard value
2) Disconnect connectors BRC2 and ASR2.
in normal state
2 harness (Disconnection or Wiring harness between BRC2 (female) (2)
Resistance Max. 1 z
defective contact) ASR2 (female) (1)
Resistance Max. 1 z
ASR2 (female) (2)
HD465-7, HD605-7 20-1067

(10)
TROUBLESHOOTING [DWNBKB]
[DWNBKB] SHUT-OFF SOLENOID VALVE: SHORT CIRCUIT (KB)

Trouble Shut-off solenoid valve: Short circuit (KB)
E01 DWNBKB BK
Contents of trouble When the output to the shut-off solenoid valve circuit is turned ON, too much current flows.
Related information

1
Possible causes
and standard value
Ground fault or short BRC2 (female) (2) ASR2 (female) (2), ASR2 (female) Max. 1 z
2 (female) (1) (1) chassis ground
circuit in wiring harness
Between wiring harness be-
Resistance between BRC2
tween BRC2 (female) (2)
(female) (2), ASR2 (female)
ASR2 (female) (1) and be- Max. 1 z
(1) BRC2 (female) (13),
tween BRC2 (female) (13)
ASR2 (female) (2)
ASR2 (female) (2)
20-1068 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DWNBKY]
[DWNBKY] SHUT-OFF SOLENOID VALVE: SHORT CIRCUIT WITH POWER SOURCE

(HOT SHORT) (KY)
Action code Failure code Controller code Shut-off solenoid valve: Short circuit with power source
Trouble
E01 DWNBKY BK (Hot short) (KY)
Contents of trouble When the output to the shut-off solenoid valve circuit is turned OFF, a current flows.
Related information

1
Possible causes 1) Turn starting switch OFF.
and standard value 2) Disconnect connectors BRC2 and ASR2.
4) Connect connector
Wiring harness between Voltage between BRC2
HD465-7, HD605-7 20-1069

(10)
TROUBLESHOOTING [DWNBMA]
[DWNBMA] SHUT-OFF SOLENOID VALVE: MALFUNCTION (MA)

Trouble Shut-off solenoid valve: Malfunction (MA)
E01 DWNBMA BK
The shut-off solenoid valve does not operate (does not move) or the pressure switch system is
Contents of trouble
defective.
Related information

Defective shut-off solenoid Check the shut-off solenoid valve and repair or replace it, if it has
1
valve abnormality (mechanical failure).
2
valve oil pressure switch 5) Turn starting switch ON.
Possible causes
in normal state 2) Disconnect connectors BRC5B and ASR7.
3
harness Wiring harness between Resistance between BRC5B
BRC5B (female) (8) ASR7 (female) (8), ASR7 (female) Max. 1 z
20-1070 HD465-7, HD605-7

(10)
TROUBLESHOOTING [DX17K4]
[DX17K4] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):

UNCONTROLLABLE (K4)
Action code Failure code Controller code ASR proportional solenoid pressure reducing valve (Right):
Trouble
E01 DX17K4 BK Uncontrollable (K4)
The ASR proportional solenoid pressure reducing valve (Right) does not return (does not move) or the
Contents of trouble
pressure switch system is defective.
Related information The state of the ASR switch (Right) can be checked with the monitoring function (Code: 39605).

Defective ASR proportional Check the ASR proportional solenoid pressure reducing valve
1 solenoid pressure reducing (Right) and repair or replace it, if it has abnormality (mechanical
valve (Right) failure).
Defective ASR proportional 3) Insert connect T-adapter.
solenoid pressure reducing 4) Connect connector.
2
valve (Right) oil pressure 5) Turn starting switch ON.
switch
Ground fault in wiring 4) Connect connector.
Possible causes harness
HD465-7, HD605-7 20-1071

(10)
20-1072 HD465-7, HD605-7

(5)
[DX17KA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):

DISCONNECTION (KA)
Trouble
When the output to the ASR proportional solenoid pressure reducing valve (Right) circuit is turned ON,
Contents of trouble
any current does not flow.
Related information

Defective ASR proportional
1 solenoid pressure reducing 4) Connect connector.
valve (Right)
Possible causes
and standard value
in normal state Disconnection in wiring 3) Connect T-adapter.
harness
(Disconnection or defective ASR3 (female) (1) Resistance Max. 1 z
contact)
Resistance Max. 1 z
ASR3 (female) (2)
HD465-7, HD605-7 20-1073

(10)
[DX17KB] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):

SHORT CIRCUIT (KB)
Trouble
E01 DX17KB BK Short circuit (KB)
When the output to the ASR proportional solenoid pressure reducing valve circuit is turned ON, any
Contents of trouble
current does not flow.
Related information

valve (Right)
Possible causes
and standard value
in normal state
Ground fault or short
2 BRC2 (female) (9) ASR3 (female) (9), ASR3 (female) Min. 1 Mz
circuit in wiring harness
Wiring harness between BRC2 (female) (9) ASR3 (fe-
male) (1) and between BRC2 (female) (19) ASR3 (fe- Min. 1 Mz
male) (2)
20-1074 HD465-7, HD605-7

(10)
[DX17KY] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):

SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) (KY)
Trouble
E01 DX17KY BK Short circuit with power source (Hot short) (KY)
When the output to the ASR proportional solenoid pressure reducing valve circuit is turned OFF, a cur-
Contents of trouble
rent flows.
Related information

valve (Right)
Possible causes
and standard value
4) Connect connector
in normal state
male) (2)
HD465-7, HD605-7 20-1075

(10)
[DX17MA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):

MALFUNCTION (MA)
Trouble
The ASR proportional solenoid pressure reducing valve (Right) does not operate (does not move) or
Contents of trouble
the pressure switch system is defective.
Related information The state of the ASR switch (Right) can be checked with the monitoring function (Code: 39605).

Defective ASR proportional Check the ASR proportional solenoid pressure reducing valve
1 solenoid pressure reducing (Right) and repair or replace it, if it has abnormality (mechanical
valve (Right) failure).
2
valve (Right) oil pressure 5) Turn starting switch ON.
switch
Possible causes
3
20-1076 HD465-7, HD605-7

(10)
[DX18K4] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):

UNCONTROLLABLE (K4)
Action code Failure code Controller code ASR proportional solenoid pressure reducing valve (Left):
Trouble
E01 DX18K4 BK Uncontrollable (K4)
The ASR proportional solenoid pressure reducing valve (Left) does not return (does not move) or the
Contents of trouble
Related information The state of the ASR switch (Left) can be checked with the monitoring function (Code: 39606).

Check the ASR proportional solenoid pressure reducing valve (Left)
valve (Left)
2
valve (Left) oil pressure 5) Turn starting switch ON.
switch
Wiring harness between Voltage between BRC5B
HD465-7, HD605-7 20-1077

(10)
20-1078 HD465-7, HD605-7

(5)
[DX18KA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):

DISCONNECTION (KA)
Trouble
When the output to the ASR proportional solenoid pressure reducing valve (Left) circuit is turned ON,
Contents of trouble
any current does not flow.
Related information

valve (Left)
Possible causes
and standard value
in normal state
2 harness (Disconnection or Wiring harness between BRC2 (female) (8)
Resistance Max. 1 z
defective contact) ASR4 (female) (1)
Resistance Max. 1 z
ASR4 (female) (2)
HD465-7, HD605-7 20-1079

(10)
[DX18KB] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):

SHORT CIRCUIT (KB)
Action code Failure code Controller code ASR proportional solenoid pressure reducing valve (Left): Short
Trouble
E01 DX18KB BK circuit (KB)
When the output to the ASR proportional solenoid pressure reducing valve circuit is turned ON, any
Contents of trouble
current does not flow.
Related information

valve (Left)
Possible causes 2) Disconnect connectors BRC2 and ASR4.
in normal state
Ground fault or short
2 BRC2 (female) (8) ASR4 (female) (8), ASR4 (female) Min. 1 Mz
circuit in wiring harness (female) (1) (1) chassis ground
male) (2)
20-1080 HD465-7, HD605-7

(10)
[DX18KY] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):

SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) (KY)
Action code Failure code Controller code ASR proportional solenoid pressure reducing valve (Left): Short
Trouble
E01 DX18KY BK circuit with power source (Hot short) (KY)
When the output to the ASR proportional solenoid pressure reducing valve circuit is turned OFF, a cur-
Contents of trouble
rent flows.
Related information

valve (Left)
Possible causes 3) Insert connect T-adapter.
and standard value 4) Connect connector
in normal state 5) Turn starting switch ON.
male) (2)
HD465-7, HD605-7 20-1081

(10)
[DX18MA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):

MALFUNCTION (MA)
Trouble
The ASR proportional solenoid pressure reducing valve (Left) does not operate (does not move) or the
Contents of trouble
Related information The state of the ASR switch (Left) can be checked with the monitoring function (Code: 39606).

Check the ASR proportional solenoid pressure reducing valve (Left)
valve (Left)
2
valve (Left) oil pressure 5) Turn starting switch ON.
switch
Possible causes
3
20-1082 HD465-7, HD605-7

(10)
TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEMS (H MODE)
H-1 Machine does not start ....................................................................................................................20-1102

H-2 Machine does not travel smoothly (machine jerks) .........................................................................20-1104
H-3 Lock-up clutch cannot be disengaged (engine stalls) .....................................................................20-1104
H-4 Excessive shock when starting or shifting.......................................................................................20-1105
H-5 Transmission does not shift up........................................................................................................20-1105
a. Does not shift up ........................................................................................................................20-1105
b. Does not shift up ........................................................................................................................20-1105
H-6 Machine lacks power or speed when traveling................................................................................20-1106
a. Abnormality at all speed ranges.................................................................................................20-1106
b. Torque converter lock-up does not engage................................................................................20-1107
c. Abnormality at specific speed ranges ........................................................................................20-1108
H-7 Time lag is excessive when starting or shifting gear .......................................................................20-1110
H-8 Torque converter oil temperature is high .........................................................................................20-1112
H-9 Torque converter oil pressure is low................................................................................................20-1113
H-10 Front brake is ineffective, or effective only on one side ..................................................................20-1114
H-11 Rear brake is ineffective, or effective only on one side ...................................................................20-1115
H-12 Steering wheel is heavy ..................................................................................................................20-1116
H-13 Steering wheel does not work .........................................................................................................20-1117
H-14 Steering wheel vibrates ...................................................................................................................20-1117
H-15 Hoist cylinder lacks lifting force (lifting speed) ...............................................................................20-1118
H-16 Hoist cylinder does not work ...........................................................................................................20-1119
H-17 Excessive hydraulic drift of dump body ...........................................................................................20-1120
HD465-7, HD605-7 20-1101

(2)
TROUBLESHOOTING H-1
H-1 Machine does not start
Ask the operator the following questions

Did the problem suddenly happen?
Yes = Internal seizure, damage
When this happened, was there any abnormal noise?
Yes = Broken part
Checks before troubleshooting

Is the oil level in the transmission case cor-
rect?
Is the torque converter, transmission input
shaft broken? (Check with the transmission
input shaft speed sensor.)
Is the drive shaft broken?
Drop in set pressure of main relief valve (torque converter valve)

Is there any dragging of the brakes?
Is any failure code related power trains dis-
played?
Defective transmission clutch seal ring, groove
Defective speed clutch (defective oil tightness)
Defective shaft seal ring in speed clutch circuit
Defective actuation of ECMV solenoid valve

Causes
Pump does not drive (defective PTO)

Air sucked in at suction side of pump
Defective operation of ECMV valve
Damage inside torque converter
Defective speed sensor function

Damage inside transmission
Seized transmission clutch
Clogged strainer
Defective pump
a b c d e f g h i j k l m n
Remedy
No. C
Problems
1 Abnormal noise comes from between pump and filter
2 Machine does not start in any speed range (Item 1 normal)
3 Machine starts normally in certain speed range
4 Machine does not start when torque converter oil temperature

rises
5 Low at every speed range
6 Set pressure of Becomes lower at certain speed range

transmission is low
7 Indicator is unstable and fluctuates
excessively
8 When pressure pickup plug is removed and engine is cranked,

no oil comes out
9 Modulation pressure is abnormal
10 Hydraulic pressure at pump outlet port is low
20-1102 HD465-7, HD605-7

(10)
TROUBLESHOOTING H-1
Clutch combination table
Clutch
No.
H L 4th 3rd 2nd 1st R
(Rotat- (Rotat-
Speed ing) ing)
range
F1
F2
F3
F4
F5
F6
F7
HD465-7, HD605-7 20-1103

(2)
TROUBLESHOOTING H-2, H-3
H-2 Machine does not travel smoothly (machine jerks)
There is hunting.
Look-up lamp flashes.

Is the oil level in the transmission case correct?
Is any failure code related power trains displayed?
Causes Remedy
Drop in main relief pressure

A. See H-6
Worn clutch seal ring
H-3 Lock-up clutch cannot be disengaged (engine stalls)

Defective actuation of lock-up ECMV solenoid valve
Defective actuation of lock-up ECMV valve

Causes
Seized lock-up clutch
a b c
Remedy C
.
No.
Problems
1 Lock-up pressure does not become "0"
2 Lock-up clutch is not disengaged even when lock-up

pressure is "0"
3 Operation of lock-up ECMV valve is normal
4 Operation of lock-up ECMV solenoid valve is normal
20-1104 HD465-7, HD605-7

(10)
H-4 Excessive shock when starting or shifting
Judgement standard
There is some shock, but it is difficult to judge if the shock is excessive or not, so judge that it is excessive in the
following cases.
It is clear that the shock has suddenly become excessive.
The shock is excessive compared with other machines of the same class.
Cause
Defective operation because of dirt caught in the ECMV pressure control valve spool and pressure detector
valve spool, or defective operation of the ECMV proportional solenoid.
H-5 Transmission does not shift up
a. Does not shift up

a Shifts up on downhill slopes.
Causes Remedy
Slipping or damage of torque converter lock-up clutch
a The above is the most probable cause, but for details, see "Torque converter lock-up does not engage".
b. Does not shift up

Causes Remedy
Defective operation of ECMV for clutch which does not shift up C
Defective piston seal ring, defective groove for clutch which does not shift up
Drop in main relief pressure A C
Clutch combination table
Clutch
No.
(Rotat- (Rotat-
Speed ing) ing)
range
F1
F2
F3
F4
F5
F6
F7
HD465-7, HD605-7 20-1105

(10)
TROUBLESHOOTING H-6
H-6 Machine lacks power or speed when traveling
a. Abnormality at all speed ranges

Is the oil level in the transmission case cor-
rect?
Excessive oil leakage inside torque converter (defective seal ring, loose plug)
Is there any external oil leakage from the
piping or valve joints?
Defective operation of torque converter relief valve, deteriorated spring

Is there any dragging of the parking brake,
Drop in set pressure of main relief valve (torque converter valve)

service brake, or retarder?
Is any failure code related power trains dis-
Cooler, piping beyond torque converter outlet port damaged

played?
Damage inside torque converter (turbine rivet broken)

Checking for abnormalities
Engine high idle speed
Torque converter stall speed
Torque converter lock-up does not engage

Machine travel speed Causes
Transmission clutch pressure
Defective torque converter freewheel

Torque converter lock-up pressure
Drop in performance of engine

Main relief pressure
Crogged strainer
Defective pump
a b c d e f g h i j k
Remedy A
A
No. C
Problems See b. TORQUE CONVERTER LOCK-UP DOES NOT ENGAGE.
2 Torque converter stall speed is high
3 Torque converter stall speed is low

Low at every speed range
4
(Item 2 abnormal)
Set pressure of Indicator is unstable and fluctuates
5
transmission is low excessively
Low after entering torque converter See TORQUE CONVERTER LOCK-UP DOES
6
lock-up NOT ENGAGE.
Hydraulic pressure at torque converter inlet port is low
7
(Items 4 6 normal)
Hydraulic pressure at torque converter outlet port is low
8
(Item 7 normal)
Pieces of iron and aluminium stuck to strainer and drain plug of
9
transmission case
10 Hydraulic pressure at pump outlet port is low
11 When oil temperature rises, oil pressure drops
20-1106 HD465-7, HD605-7

(10)
TROUBLESHOOTING H-6
b. Torque converter lock-up does not engage

Yes = Internal seizure, damage
When this happened, was there any abnormal noise?
Yes = Broken part

Is there any external oil leakage ?
Is electricity flowing to the lock-up solenoid?
(Use a checker)

Main relief pressure
Lock-up oil pressure
Defective operation of lock-up ECMV solenoid valve spool

Main travel speed
Defective operation of lock-up ECMV valve spool

Drop in set pressure of main relief valve
Causes
Worn lock-up clutch piston seal ring

Defective lock-up ECMV solenoid
Cracked lock-up clutch case

Worn lock-up clutch disc
a b c d e f g
Remedy
No.
Problems
1 Main relief pressure is low
2 With Item 1 normal, lock-up pressure is low or "0"
3 Solenoid is normal in Item 2 (proper continuity, no short circuit)
4 Solenoid is defective in Item 2 (no continuity, there is short circuit)
5 With Items 1 4 normal, lock-up pressure is low
6 Oil pressure is normal in Item 5
7 Lock-up pressure is low and main pressure is also low
8 Lock-up takes time to engage
HD465-7, HD605-7 20-1107

(10)
TROUBLESHOOTING H-6
c. Abnormality at specific speed ranges

Is the oil level in the transmission case correct? Clutch combination table
Is there any dragging of the parking brake, ser-
vice brake, or retarder? Clutch
No.
Is any failure code related power trains dis- H L 4th 3rd 2nd 1st R
played? (Rotat- (Rotat-
Speed ing) ing)
range
Machine travel speed R
F1
F2
F3
F4
F5
F6
F7
Remedy
No.
Problems
(1) F1 is normal, but F2 is defective
1
(2) Returns to normal when replaced with any ECMV except 2nd.
(1) F2 is normal, but F1 is defective or only F1 is defective

2
(2) Returns to normal when replaced with any ECMV except 1st.
(1) F1 and F2 are normal, but F3 is defective

3
(2) Returns to normal when replaced with any ECMV except H.
(1) F1, F2 and F3 are normal, but F4 is defective

4
(2) Returns to normal when replaced with any ECMV except 3rd.
(1) F1 F5 are normal, but F6 is defective

5
(2) Returns to normal when replaced with any ECMV except 4th.
(1) F3, F5, and F7 are normal, but others are defective
6
(2) Returns to normal when replaced with any ECMV except L.
(1) Only R is defective

7
(2) Returns to normal when replaced with any ECMV except R.
a Remove all the mud and dirt from around the ECMV, and clean it before replacing.
a After replacing, tighten the ECMV mounting bolts to the specified tightening torque.
ECMV mounting bolt : 8.0 10.0 Nm {0.8 1.0 kgm}
20-1108 HD465-7, HD605-7

(7)
Causes
a
H clutch disc worn or seized, seal ring worn
b
L clutch disc worn or seized, seal ring worn
c
4th clutch disc worn or seized, seal ring worn
HD465-7, HD605-7
d
3rd clutch disc worn or seized, seal ring worn
TROUBLESHOOTING
e
2nd clutch disc worn or seized, seal ring worn
f
1st clutch disc worn or seized, seal ring worn
g
R clutch disc worn or seized, seal ring worn
h
Defective operation of H clutch ECMV
i
Defective operation of L clutch ECMV
j
Defective operation of 4th clutch ECMV
k
Defective operation of 3rd clutch ECMV
l
Defective operation of 2nd clutch ECMV
m
Defective operation of 1st clutch ECMV
n
Defective operation of R clutch ECMV
(7)
H-6
20-1109
TROUBLESHOOTING H-7
H-7 Time lag is excessive when starting or shifting gear

Is there any external oil leakage from the piping or valve joints?
Is operation of control valve normal?
Checking for abnormalities Clutch combination table

See the STANDARD VALUE TABLE to check
Clutch
if the time lag is actually excessive. No.
(Rotat- (Rotat-
Speed ing) ing)
range
F1
F2
F3
F4
F5
F6
F7
Remedy
No.
Problems
1 Abnormal noise comes from pump
2 There is time lag when transmission is placed in any speed range
3 F1 is normal, but there is time lag when shifting to F2
4 F2 is normal, but there is time lag when shifting to F1
5 F1 and F2 are normal, but there is time lag when shifting to F3
6 F1, F2, and F3 are normal, but there is time lag when shifting to F4
7 F1 - F5 are normal, but there is time lag when shifting to F6
8 F3, F5, and F7 are normal, but there is time lag when in other speed ranges
9 There is time lag in R
10 Transmission modulating pressure is low when placed in any speed range
11 Torque converter oil temperature goes above operating range
20-1110 HD465-7, HD605-7

(2)
Causes
C
Clogged strainer
b
c
Defective pump
HD465-7, HD605-7
d
Defective oil tightness in rotating clutch
TROUBLESHOOTING
e
Defective shaft seal ring in rotating clutch circuit
f
Drop in set pressure of main relief valve
g
H clutch disc worn or defective seal ring, worn groove
h
L clutch disc worn or defective seal ring, worn groove
i
4th clutch disc worn or defective seal ring, worn groove
j
3rd clutch disc worn or defective seal ring, worn groove
k
2nd clutch disc worn or defective seal ring, worn groove
l
1st clutch disc worn or defective seal ring, worn groove
m
R clutch disc worn or defective seal ring, worn groove
n
Defective operation of H clutch ECMV
o
Defective operation of L clutch ECMV
p
Defective operation of 4th clutch ECMV
q
Defective operation of 3rd clutch ECMV
r
Defective operation of 2nd clutch ECMV
s
Defective operation of 1st clutch ECMV
t
Defective operation of R clutch ECMV
(7)
20-1111
H-7
TROUBLESHOOTING H-8
H-8 Torque converter oil temperature is high

Does oil temperature go up when torque converter is stalled and go down when torque converter is not
stalled?
Yes = Normal (If torque converter is stalled frequently, however, selection of speed range is
incorrect)

Is oil level in transmission case correct?

Use STANDARD VALUE TABLE to judge if torque converter oil temperature is actually high.
a If oil temperature is normal but oil temperature gauge on machine goes above operating range.
odefective oil temperature gauge
Oil leakage inside torque converter (defective seal ring, loose bolt,
Defective operation of torque converter relief valve
Causes
crack in pump, turbine)

Clogged strainer
Defective pump
Clogged filter
Torque
Tank-pump converter
a b c d e f
Remedy
No. C
Problems
1 Pump makes abnormal noise when oil temperature is low
2 High idle and low idle speeds are low
3 Torque converter outlet port oil pressure is low
4 Torque converter inlet port oil pressure is low
5 Transmission modulating pressure is low
6 Excessive leakage inside torque converter
If troubleshooting shows
that all other items are
normal, this is the cause.
20-1112 HD465-7, HD605-7

(10)
TROUBLESHOOTING H-9
H-9 Torque converter oil pressure is low

Is there any external oil leakage from the piping or valve joints?

Pump outlet port oil pressure
Clogged hydraulic pump suction strainer or suction of air into circuit
Drop in set pressure of torque converter relief valve
Excessive leakage inside torque converter

Causes
Defective hydraulic pump
a b c d
Remedy
No. C
Problems
1 Abnormal noise comes from pump
2 Oil pressure is low between pump and relief valve
3 Torque converter inlet port pressure is low

Transmission and lock-up pressures are normal, but torque
4
converter inlet pressure is low
When set pressure of torque converter relief valve is adjusted,
5
inlet pressure becomes high
HD465-7, HD605-7 20-1113

(2)
TROUBLESHOOTING H-10
H-10 Front brake is ineffective, or effective only on one side

Is the brake pedal play correct?
Is there any leakage of oil from the brake
piping or deformation of the piping?
Drop in front brake accumulator gas pressure (gas leakage, defective

Is the tire inflation and tread condition nor-
mal?
Is any failure code related to the brakes
displayed?
Air sucked in at suction side of brake operating pump

Is the front brake cut-off switch turned on?
Defective brake operating pump drive system (PTO)
Defective front brake accumulator charge valve
Defective operation of front brake cut valve

Causes
Defective wheel brake piston seal

Defective brake operating pump
Defective brake valve (front)
Air in brake circuit

piston seal
a b c d e f g h i
Remedy
No.
Problems
1 Brake has no effect only when brake pedal is depressed
2 When brake pedal is depressed, it is light
3 When brake pedal is depressed, it is heavy
4 Extremely large operating effort is needed to obtain specified

braking effect
5 Hydraulic and steering do not work
6 Abnormal noise is heard from around PTO
7 Abnormal noise is heard from around transmission oil pan or

PPC pump
8 Accumulator charge pressure is low
9 Brake immediately loses power after engine is stopped
10 There is time lag before brake starts to take effect
11 Brake oil pressure is low
12 When air is bled from brake system, air comes out
13 When front brake cut-off switch is turned ON (When its lower

part is pressed), front brake is not released
20-1114 HD465-7, HD605-7

(10)
H-11 Rear brake is ineffective, or effective only on one side

Is the brake pedal play correct?
Is there any leakage of oil from the brake
piping or deformation of the piping?
Drop in rear brake accumulator gas pressure (gas leakage, defective

Is the tire inflation and tread condition nor-
Defective retarder solenoid valve (Proportional reducing valve)

mal?
Is any failure code related to the brakes dis-
played?
Air sucked in at suction side of brake operating pump

Defective brake operating pump drive system (PTO)
Defective rear brake accumulator charge valve
Defective operation of wheel brake piston

Causes
Defective wheel brake piston seal

Defective brake operating pump
Breakage inside wheel brake

Defective brake valve (rear)
Defective slack adjuster
Defective retarder lever

Worn wheel brake disc
Air in brake circuit
Improper axle oil

piston seal)
a b c d e f g h i j k l m n O
Remedy
No.
Problems
1 Brake has no effect only when brake pedal is depressed
2 When brake pedal is depressed, it is light
3 When brake pedal is depressed, it is heavy
4 Even when retarder lever is pulled, retarder has no effect
5 Extremely large operating effort is needed to obtain specified

braking effect
6 When brakes are applied, abnormal noise is heard from brake

portion of axle
7 Hydraulic and steering do not work
8 Abnormal noise is heard from around PTO
9 Abnormal noise is heard from around transmission oil pan or

PPC pump
10 When oil is drained from inside axle case, large amounts of

metal particles are found
11 Accumulator charge pressure is low
12 Brake immediately loses power after engine is stopped
13 There is time lag before brake starts to take effect
14 Brake oil pressure is low
15 Brake disc wear amount is high
16 When air is bled from brake system, air comes out
HD465-7, HD605-7 20-1115

(10)
H-12 Steering wheel is heavy

Is the oil level in the hydraulic tank correct?
Is there any external oil leakage between the pump and steering valve?
Is the steering wheel play correct?
Is any failure code related steerings displayed?

Operating effort of steering wheel
Time taken to turn the steering wheel from
lock to lock
Relief pressure of steering circuit
Drop in relief valve set pressure or defective sealing
Defective operation of spool or stuck spool

Causes
Defective opening of check valve

Air sucked in at suction end
Defective steering cylinder

Defective steering pump
Defective steering valve

Crushed suction tube
Defective hoist pump

Clogged strainer
Demand
valve
a b c d e f g h i j
Remedy A
No. C
Problems
1 Circuit pressure is too high at engine low idle or pressure rises

to relief pressure
2 Relief pressure in steering circuit is too low
3 Hoist force is also low
4 Item 3 is abnormal and noise of oil blowing is heard from relief

valve
5 Relief pressure is low at end of cylinder stroke

(Items 1 4 normal)
7 When steering wheel is turned to right (left), oil flows out

continuously when hose on opposite side is removed
8 Condition is normal at engine low idle
9 Pump discharge amount is too low
10 Item 3 is normal but speed is slow
11 Excessive play in steering wheel
20-1116 HD465-7, HD605-7

(10)
H-13 Steering wheel does not work

Is there any external oil leakage between
pump and steering valve?
Is the steering wheel play correct?
Is any failure code related steerings dis-
played?


Relief pressure
Causes

Air sucked in at suction side
Defective steering cylinder

Defective steering valve

Defective hoist pump

Clogged strainer Demand
valve
a b c d e f g h i j k
Remedy A
No. C
Problems
1 Hoist cylinder also does not work
2 When pressure pickup port plug is removed and engine is

cranked, no oil comes out
3 Circuit pressure is too high at engine low idle, or pressure rises

to relief pressure (Item 2 normal)
4 Hoist is normal
5 Relief pressure is low at end of cylinder stroke (Item 4 normal)
6 Item 5 is abnormal and noise of oil blowing is heard from relief

valve
8 Steering wheel works when engine is at low idle
9 When steering wheel is turned to right (left) and hose on oppo-

site side is removed, rod does not move but oil flows out
10 Pump discharge amount is too low
11 Excessive play in steering wheel
H-14 Steering wheel vibrates

Is any failure code related steerings displayed?
Causes Remedy
Air in hydraulic oil A
Leakage of air inside steering cylinder
HD465-7, HD605-7 20-1117

(10)
H-15 Hoist cylinder lacks lifting force (lifting speed)

Is the actuation of the control levers normal?
Is the input signal value of the dump lever in the normal range?
Is any failure code related dump bodys dis-
Drop in dump EPC circuit oil pressure or defective operation of EPC valve
played?
Is there any external oil leakage from between
pump and cylinder?
Drop in safety valve set pressure or defective sealing

Relief pressure

Body lifting speed

Causes
Drop in performance of hydraulic pump
Drop in performance of steering pump

Defective hoist cylinder

Defective dump lever

Clogged strainer
Demand valve Hoist valve
Remedy A A A
No. C C
Problems
1 Steering wheel is also heavy
2 Steering wheel is normal
3 Item 1 is defective and hoist circuit relief pressure is low

Item 3 is abnormal and noise of oil blowing is heard from relief
4
valve
Hoist circuit pressure is too high at engine high idle
5
(Items 1 4 are normal)
6 Only hoist circuit relief pressure is low
7
valve
8 Dump body rises irregularly
9 Pump discharge amount is low
10 Measured dump EPC valve oil pressure is low
11 Excessive hydraulic drift of hoist cylinde
12 Items 1 10 are normal but dump body lifting speed is slow
20-1118 HD465-7, HD605-7

(10)
H-16 Hoist cylinder does not work

Yes = Seizure, damage to equipment
Had drop in lifting speed or other symptoms
appeared before?
Drop in dump EPC circuit oil pressure or defective operation of EPC valve
Yes = Worn parts, deteriorated spring, etc.

Drop in safety valve set pressure or defective sealing

Is the input signal value of the dump lever in

the normal range?
Is any failure code related dump bodys

displayed?

Causes

Relief pressure
Crushed pump suction tube
Defective hydraulic pump
Defective hoist cylinder
Defective dump lever

Clogged strainer
Demand valve Hoist valve
Remedy A A A
No. C
Problems
When pressure pickup port plug is removed and engine is
1
cranked, no oil comes out
2 Steering also does not work
3 Steering is normal, only hoist does not work
4 In Item 2, hoist circuit relief pressure is low

5
valve
6 Only hoist circuit relief pressure is low at engine high idle
7
valve
Hoist circuit pressure is too high at engine low idle or
8
pressure rises to relief pressure (Items 1 - 5 normal)
9 Works when engine is at low idle
10 Pump discharge amount is low

When hoist lever is operated to RAISE, and hose on opposite
11
side is removed, cylinder does not move, but oil comes out
12 Measured dump EPC valve oil pressure is low
HD465-7, HD605-7 20-1119

(10)
H-17 Excessive hydraulic drift of dump body

Is any failure code related dump bodys displayed?

Hydraulic drift of cylinder
Causes
Defective hoist cylinder piston ring
Defective sealing of valve spool
a b
Remedy
No.
Problems
1 When engine is stopped with Oil continues to flow out

body fully raised and head pip-
2 ing is removed Oil does not continue to flow out
20-1120 HD465-7, HD605-7

(10)
TROUBLESHOOTING OF ENGINE SYSTEM
(S MODE)
Points to remember when troubleshooting.................................................................................................20-1152

Method of using troubleshooting charts .....................................................................................................20-1153
S- 1 Starting performance is poor (starting always takes time) .............................................................20-1156
S- 2 Engine does not start ....................................................................................................................20-1159
a) Engine does not turn ................................................................................................................20-1159
b) Engine turns but no exhaust smoke comes out (fuel is not being injected) .............................20-1160
c) Exhaust smoke comes out but engine does not start (fuel is being injected) ..........................20-1162
S- 3 Engine does not pick up smoothly (follow-up is poor) ...................................................................20-1164
S- 4 Engine stops during operations .....................................................................................................20-1166
S- 5 Engine does not rotate smoothly (hunting) ....................................................................................20-1168
S- 6 Engine lacks output (or lacks power).............................................................................................20-1170
S- 7 Exhaust smoke is black (incomplete combustion) ........................................................................20-1172
S- 8 Oil consumption is excessive (or exhaust smoke is blue) ............................................................20-1175
S- 9 Oil becomes contaminated quickly ...............................................................................................20-1176
S-10 Fuel consumption is excessive ......................................................................................................20-1177
S-11 Oil is in coolant, or water spurts back, or water level goes down .................................................20-1178
S-12 Oil pressure warning lamp lights up (drop in oil pressure).............................................................20-1179
S-13 Oil level rises .................................................................................................................................20-1180
S-14 Coolant temperature becomes too high (overheating) .................................................................20-1181
S-15 Abnormal noise is made ................................................................................................................20-1182
S-16 Vibration is excessive ....................................................................................................................20-1183
HD465-7, HD605-7 20-1151

(10)
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

Stop the machine in a level place, and check that the safety pins and blocks are securely fitted, and the
parking brake is securely applied.
When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
If the radiator cap is removed when the engine is still hot, boiling water may spurt out and cause serious
burns. Always wait for the coolant temperature to go down before removing the radiator cap.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative () terminal of the battery first.
When removing a plug or cap from a location which is under pressure from oil, coolant, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent
reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand
the structure and function. However, a short cut to effective troubleshooting is to ask the operator various
questions to form some idea of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not 3. Checks before troubleshooting

hurry to disassemble the components 1) Is there any sign of abnormality in the
If components are disassembled immediately machine or engine?
any failure occurs: 2) Always carry out the Checks before starting.
Parts that have no connection with the failure 3) Carry out other checks if necessary.
or other unnecessary parts will be disassem- 4) Other maintenance items can be checked
bled externally, so check any item that is consid-
It will become impossible to find the cause of ered to be necessary.
the failure. 5) Check for any error display on the controller.
It will also cause a waste of man-hours, parts, or
oil or grease, and at the same time, will also lose 4. Confirming failure
the confidence of the user or operator. Confirm the extent of the failure yourself, and
For this reason, when carrying out troubleshoot- judge whether to handle it as a real failure or as
ing, it is necessary to carry out thorough prior a problem with the method of operation, etc.
investigation and to carry out troubleshooting in a When operating the machine to re-enact the
accordance with the fixed procedure. troubleshooting symptoms, do not carry out
any investigation or measurement that may
2. Points to ask user or operator make the problem worse.
1) Have any other problems occurred apart
from the problem that has been reported? 5. Troubleshooting
2) Was there anything strange about the Use the results of the investigation and inspec-
machine before the failure occurred? tion in Items 2 4 to narrow down the causes of
3) Did the failure occur suddenly, or were there failure, then use the troubleshooting matrix or
problems with the machine condition before flowchart to locate the position of the failure
this? exactly.
4) Under what conditions did the failure occur? a The basic procedure for troubleshooting is
5) Had any repairs been carried out before the as follows.
failure? When were these repairs carried 1) Start from the simple points.
out? 2) Start from the most likely points.
6) Has the same kind of failure occurred 3) Investigate other related parts or informa-
before? tion.
6. Measures to remove root cause of failure

Even if the failure is repaired, if the root cause of
the failure is not repaired, the same failure will
occur again.
To prevent this, always investigate why the
problem occurred. Then, remove the root
cause.
20-1152 HD465-7, HD605-7

(10)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshoot-
ing. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspeciton with-
out using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.
[Questions]
Sections (A) + (B) in the chart on the right corre-
sponds to the items where answers can be
obtained from the user. The items in (B) are
items that can be obtained from the user,
depending on the user's level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under (C) in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information (A) that he has obtained from the
user and the results of (C) that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are
marked with , and of these, causes that have a
high probability are marked with .
Check each of the [Questions] and [Check items]
in turn, and marked the or in the chart for
items where the problem appeared. The vertical col-
umn (Causes) that has the highest number of points
is the most probable cause, so start troubleshooting
for that item to make final confirmation of the cause.
As a rule, do not use it when calculating the points
for locating the cause, but it can be included if nec-
essary to determine the order for troubleshooting.
Use the in the Cause column as reference for
[Degree of use (Operated for long period)] in the
[Questions] section as reference.
HD465-7, HD605-7 20-1153

(10)
Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms
have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became
weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five causes.
Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
S-7 Exhaust smoke is black (incomplete combustion)

General causes why exhaust smoke is black
Insufficient intake of air
Defective condition of fuel injection
Excessive injection of fuel
Defective HPI sensor
Defective HPI actuator
Normal output is not applied
a See Troubleshooting S-6
20-1154 HD465-7, HD605-7

(10)
Five causes
Step 1
Clarify the relationship between the three symptoms in

the [Questions] and [Check items] section and the five
Cause items in the vertical column.
Three symptoms
Step 2
Add up the total of and marks where the horizontal
limes for the three symptoms and the vertical columns for
the causes intersect.
(1) Clogged air cleaner element:
(2) Defective contact of valve, valve seat:
(3) Leakage of air between turbocharger
and head:
(4) Worn piston ring, cylinder liner:
(5) Defective timing rail pressure sensor:
Step 3
The calculation in Step 2 shows that the closest
relationship is with [Worn piston ring, cylinder liner].
Follow this column down to the troubleshooting area and
carry out the troubleshooting item marked .
The Remedy is given as [Clean], so carry out cleaning,
and the exhaust gas color should return to normal.
HD465-7, HD605-7 20-1155

(10)
TROUBLESHOOTING S-1
S-1 Starting performance is poor (starting always takes time)

General causes why starting performance is poor Causes
Defective electrical system
Defective preheating circuit (when starting in low temperatures)

Insufficient supply of fuel
Improper selection of fuel
Defective contact of valve, valve seat
Clogged timing rail actuator screen

Loose piping, fuel filter, entry of air
Defective or deteriorated battery

Worn piston ring, cylinder liner
Defective alternator regulator

Clogged air cleaner element
Defective injector check ball

Clogged fuel filter, strainer
Cut, worn injector O-ring

Defective shut-off valve
Clogged fuel tank cap
Defective fuel pump
Defective alternator
Defective injector
Confirm recent repair history
Degree of use of machine Operated for long period
Starting performance became worse gradually
Engine starts easily when warm
Questions
Non-specified fuel is being used

Replacement of filters has not been carried out according to Operation Manual
Engine oil must be added more frequently
Charge caution lamp lights up
When preheating, preheating indicator lamp does not light up
Dust indicator is red
Air breather hole in fuel tank cap is clogged
Starting motor cranks engine slowly
When engine is Fuel pump outlet port coupler is pushed, almost no fuel comes out
cranked with
starting motor, Fuel pump outlet port coupler is pushed, air comes out together with fuel
Check items
When exhaust manifold is touched immediately after starting engine, temperature

of some cylinders is low
Engine does not pick up smoothly, and combustion is irregular
There is hunting from engine (rotation is irregular)
Blow-by gas is excessive
Difficult to stop engine
Inspect air cleaner element directly

When compression pressure is measured, it is found to be low
Inspect fuel filter, strainer directly
When negative pressure at inlet port of fuel pump is measured, it is found to be high
When pressure at outlet port of fuel pump is measured, it is found to vary
When pressure at outlet port of fuel pump is measured, it is found to be low
Inspect fuel pump directly
Troubleshooting
Inspect fuel shut-off valve directly

Inspect timing rail actuator screen directly
When temperature of exhaust gas of each cylinder is measured, there are some
cylinders that are low
Inspect injector directly
When specific gravity of electrolyte and voltage of battery are measured, one of
them is low
When starting switch is turned to HEAT, heater mount does not become warm
Is voltage 26 - 30V between alternator terminal B and terminal E with Yes
engine at low idle? No
Inspect sensor directly (Output voltage and resistance)
Inspect actuator directly (Resistance and filter for clogging)
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
20-1156 HD465-7, HD605-7

(10)
TROUBLESHOOTING S-1
Causes (*1) If the following failure codes are displayed, carry out
the troubleshooting in "ENG mode". (If any of the
following failure codes is not displayed, they are not
probably the cause of the trouble. In this case,
inspect the other devices for the cause.)
Defective intake manifold temperature sensor
[C514LK]:Abnormality in fuel rail actuator

[C112LK]:Abnormality in timing rail actuator
Defective atmospheric pressure sensor
Defective coolant temperature sensor

Defective fuel pump pressure sensor
Defective timing rail pressure sensor
[C318LK]:Abnormality in fuel pump actuator

Defective fuel rail pressure sensor
Defective fuel pump actuator (*1)

Defective timing rail actuator (*1)
Defective boost pressure sensor
Defective fuel rail actuator (*1)

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
HD465-7, HD605-7 20-1157

(10)
TROUBLESHOOTING S-2
S-2 Engine does not start

a) Engine does not turn
General causes why engine does not turn

Internal parts of engine seized
a See Troubleshooting S-4. Causes
Defective electrical system
Problem in power train (troubleshooting for machine)
Defective starting motor safety relay or safety switch

a See the manual for the machine.
Defective battery terminal connection

Defective starting circuit wiring

Broken flywheel ring gear
Defective starting switch
Defective starting motor

Defective battery relay
Questions
Condition of horn when starting Horn does not sound

switch is turned ON Horn volume is low
Battery electrolyte is low
Battery terminal is loose
When starting switch is turned to ON, there is no clicking sound from battery relay
When starting switch is turned to START, starting pinion does not move out
Check items
Speed of rotation is low

When starting switch is turned Makes grating noise
to START, starting pinion moves
out, but Soon disengages again
Makes rattling noise and does not turn
Inspect flywheel ring gear directly

Troubleshooting
When specific gravity of electrolyte and voltage of battery are measured, one of them is low
When terminal B and terminal C of starting switch are connected, engine starts
Turn starting switch
There is no 24V between battery relay terminal B and terminal E
OFF, connect cord,
and carry out When terminal B and terminal C of starting motor are connected, engine starts
troubleshooting at
(*1)
When terminal B and terminal C of safety relay are connected, engine starts
ON
When terminal of safety switch and terminal B of starting motor are connected, engine starts
Replace
Replace
Replace
Replace
Replace
Replace
Correct

Remedy
(*1) Carry out troubleshooting of machine
HD465-7, HD605-7 20-1159

(10)
TROUBLESHOOTING S-2
b) Engine turns but no exhaust smoke comes out (fuel is not being injected)
General causes why engine turns but no exhaust smoke comes out
Fuel is not being supplied
Supply of fuel is extremely small
Improper selection of fuel (particularly in winter)
Defective HPI sensor Causes

Defective fuel shut-off valve wiring

Clogged timing actuator screen
Broken fuel pump drive shaft
Defective fuel shut-off valve
Insufficient fuel in tank
Questions
Exhaust smoke suddenly stopped coming out (when starting again)

Starts when engine is warm
When fuel tank is inspected, it is found to be empty
Rust and water are found when fuel tank is drained
When fuel filter is drained, fuel does not come out
Check items
There is leakage from fuel piping

Wiring of fuel shut-off valve is loose
Cylinder block ground wiring is loose
When engine is cranked with Fuel pump outlet port coupler is pushed, almost no fuel comes out
starting motor, and Fuel pump outlet port coupler is pushed, air comes out together with fuel
Troubleshooting
Inspect fuel pump drive shaft directly

Inspect fuel shut-off valve directly
When starting switch is turned to START, voltage [24V] is not generated between fuel shut-off valve connector
pins
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Remedy
Add
20-1160 HD465-7, HD605-7

(10)
TROUBLESHOOTING S-2
(*1) If the following failure codes are displayed, carry out

Causes probably the cause of the trouble. In this case,
Defective intake manifold temperature sensor
Defective coolant temperature sensor


Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
HD465-7, HD605-7 20-1161

(10)
TROUBLESHOOTING S-2
c) Exhaust smoke comes out but engine does not start (fuel is being injected)
General causes why exhaust smoke comes out but engine does not start
Lack of rotating force due to defective electrical system
Insufficient supply of fuel Causes
Defective dynamic valve system (valve, rocker arm, etc.)

Improper selection of fuel and oil
Defective preheating heater circuit

Clogged timing actuator screen

Defective fuel pump
Defective injector
Suddenly failed to start
Questions

Starts when engine is warm
When preheating, preheating indicator lamp does not light up
When fuel filter is drained, no fuel comes out
Check items

Starting motor cranks engine slowly
When engine is cranked, abnormal noise is generated around cylinder head
cranked with starting
motor, and Fuel pump outlet port coupler is pushed, air comes out together with fuel

Inspect dynamic valve system directly
Troubleshooting
When fuel filter, strainer directly

When temperature of exhaust gas of each cylinder is measured, there are some cylinders that are low
When specific gravity of electrolyte and voltage of battery are measured, one of them is low
When starting switch is at HEAT, heater mount does not become warm
Inspect fuel rail actuator directly
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Remedy
20-1162 HD465-7, HD605-7

(10)
Replace Defective atmospheric pressure sensor
Replace Defective boost pressure sensor
Replace Defective fuel rail pressure sensor
Replace Defective timing rail pressure sensor
Replace Defective fuel pump pressure sensor
Replace Defective coolant temperature sensor Causes
HD465-7, HD605-7
Replace Defective intake manifold temperature sensor
Replace Defective fuel rail actuator (*1)
TROUBLESHOOTING
Replace Defective timing rail actuator (*1)

Replace Defective fuel pump actuator (*1)
Replace Clogged fuel rail actuator

(10)
20-1163
S-2
TROUBLESHOOTING S-3
S-3 Engine does not pick up smoothly (follow-up is poor)

General causes why engine does not pick up smoothly Causes
Defective condition of fuel spray
Improper fuel used
Abnormality in fuel control system
Defective contact of valve and valve seat



(See Troubleshooting S-6)

Improper valve clearance

Seized turbocharger
Defective fuel pump

Defective injector
Engine pick-up suddenly became worse
Questions

Rust and water are found when fuel is drained
When engine is cranked Fuel pump outlet port coupler is pushed, almost no fuel comes out
with starting motor, and Fuel pump outlet port coupler is pushed, air comes out together with fuel
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
Check items
Blue under light load

Color of exhaust gas
Black
Clanging sound is heard from around cylinder head
Noise of interference is heard from around turbocharger
High idle speed under no load is normal, but speed suddenly drops when load is applied

When turbocharger is rotated by hand, it is found to be heavy
Inspect valve clearance directly
Troubleshooting

When temperature of injector of each cylinder is measured, there are some cylinders that are low
When intake air pressure (boost pressure) is measured, it is found to be normal
Inspect for air leakage
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Clean
Clean
Remedy
20-1164 HD465-7, HD605-7

(10)
TROUBLESHOOTING S-3
Air leakage from piping between turbocharger and cylinder head

Replace
Replace
Replace
Replace
Replace
HD465-7, HD605-7 20-1165

(10)
TROUBLESHOOTING S-4
S-4 Engine stops during operations

General causes why engine stops during operations
Seized parts inside engine
There is overheating Causes
a See Troubleshooting S-14.
Broken dynamic valve system (valve, rocker arm, etc.)

Problem in power train (troubleshooting for machine)
Defective in power train (troubleshooting for machine)

Broken, seized main bearing, connecting rod bearing
Broken auxiliary equipment (pump, compressor, etc.)


Low power source voltage of controller
Broken, seized piston, connecting rod
Broken fuel pump drive shaft

Broken, seized gear train
Defective injector
Abnormal noise was heard and engine stopped suddenly
Engine overheated and stopped
Condition when engine stopped
Engine stopped slowly
Questions
There was hunting and engine stopped

Fuel level warning lamp lights up
Metal particles are found when oil is drained
Does not turn at all
When it is attempted
Check items
Turns in opposite direction

to turn by hand using
barring tool Moves amount of gear backlash
Fuel pump shaft does not turn
Engine turns, but stops when load is applied to machine

Carry out troubleshooting of machine
Inspect piston, connecting rod directly

Inspect main bearing, connecting rod directly
Inspect gear train directly
Troubleshooting

Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is removed
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Remedy
Add
20-1166 HD465-7, HD605-7

(10)
TROUBLESHOOTING S-4


Defective fuel shut-off valve

Clogged fuel inlet circuit
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
HD465-7, HD605-7 20-1167

(10)
TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly (hunting)

General causes why engine does not rotate smoothly
Causes
Air in fuel system
Defective governor mechanism
High resistance, clogged fuel return circuit

Defective actuation of timing rail actuator

Defective actuation of fuel rail actuator
Defective injector check ball


Defective fuel pump
Defective injector
Questions
Occurs at a certain speed range

Occurs at low idle
Condition of hunting
Occurs even when speed is raised
Occurs on slopes
Rust, water are found when fuel tank is drained
Leakage from fuel piping
Check items
Engine speed sometimes rises too far
Engine is difficult to stop

Troubleshooting

When flow of spill fuel is checked visually, it is found to be low
Inspect fuel rail actuator screen directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
20-1168 HD465-7, HD605-7

(10)
Replace Defective atmospheric pressure sensor
Replace Defective boost pressure sensor
Replace Defective fuel rail pressure sensor
Replace Defective timing rail pressure sensor
Replace Defective fuel pump pressure sensor
Replace Defective fuel pump actuator (*1)
Causes
HD465-7, HD605-7
Defective in throttle sensor
Replace Defective in speed sensor
TROUBLESHOOTING
Replace Clogged fuel rail actuator screen

Replace Clogged timing rail actuator screen
[C318LK]: Abnormality in fuel pump actuator
this case, inspect the other devices for the cause.)
(*1) If the following failure code is displayed, carry out
played, it is not probably the cause of the trouble. In

the troubleshooting in "ENG mode". (If it is not dis-
(10)
20-1169
S-5
TROUBLESHOOTING S-6
S-6 Engine lacks output (or lacks power)

a Measure the engine speed and judge if the problem is in the engine or on the machine.
General causes why engine lacks output Causes

Improper fuel used
(if non-specified fuel is used, output drops)
There is overheating

a See Troubleshooting S-14.
Improper adjustment of valve clearance


Seized turbocharger, interference

Wrong pare number of controller

High fuel temperature
Defective fuel pump

Defective injector
Suddenly
Power was lost
Questions
Gradually
Dust indicator lamp is red
Black
Check items

Engine pickup is poor and combustion is irregular
High idle speed of engine is low

Troubleshooting

Check part No. of controller calibration data
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Clean
Remedy
20-1170 HD465-7, HD605-7

(10)
TROUBLESHOOTING S-6


Defective controller calibration data

Defective throttle sensor

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean

HD465-7, HD605-7 20-1171

(10)
TROUBLESHOOTING S-7
S-7 Exhaust smoke is black (incomplete combustion)

General causes why exhaust smoke is black
Defective condition of fuel injection Causes
Leakage of air between turbocharger and cylinder head


Improper adjustment of valve clearance
Failure timing rail pressure sensor

Seized turbocharger, interference

Crushed, clogged muffler

Defective fuel pump
Defective injector
Suddenly became black
Color of exhaust gas Gradually became black
Questions

Suddenly
Power was lost
Gradually
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp
Check items

Exhaust noise is abnormal
Engine pickup is poor and combustion is irregular
Inspect air cleaner directly

Troubleshooting

When muffler is removed, exhaust sound improves
Inspect between turbocharger and cylinder head directly
Abnormality in timing rail pressure sensor system is indicated (*2)
Inspect sensor directly (Output voltage)
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Remedy
20-1172 HD465-7, HD605-7

(10)
TROUBLESHOOTING S-7

[C112LK]: Abnormality in timing rail actuator
(*2) If an failure code of the timing rail pressure sensor
system is displayed, carry out the troubleshooting in
"EA mode".
HD465-7, HD605-7 20-1173

(10)
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive (or exhaust smoke is blue)

a To prevent the oil from leaking up or down in
the turbocharger, do not run the engine at idle for more
than 20 minutes continuously (both low and high idle).
Causes
General causes why oil consumption is excessive

Abnormal combustion of oil
External leakage of oil
Worn seal at turbine end

Worn seal at blower end
Wear of parts in lubrication system
Worn, damaged valve (stem, guide, seal)
Leakage from oil pan or cylinder head

Clogged breather or breather hose
Dust sucked in from intake system
Leakage from oil filter or oil cooler

Leakage from oil drain plug

Too much engine oil added
Worn, broken rear oil seal
Leakage from oil piping

Broken piston ring
Broken oil cooler

Turbocharger
Questions

Oil consumption suddenly increased
Engine oil becomes contaminated quickly
Oil level is above H level on gauge
Outside of engine is dirty with oil
There are loose piping clamps in intake system
Inside of turbocharger intake pipe is dirty with oil
Check items
Inside of exhaust pipe is dirty with oil

There is oil in engine coolant
Oil level in clutch chamber or damper chamber rises
Exhaust smoke is blue under light load
Excessive
Amount of blow-by gas
None
When intake manifold is removed, dust is found inside

Excessive play of turbocharger shaft
Troubleshooting
When intake manifold is removed, inside is found to be dirty with oil

Inspect breather element directly
Inspect rear oil seal directly
There is external leakage of oil from engine
Pressure-tightness test of oil cooler shows there is leakage
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
HD465-7, HD605-7 20-1175

(10)
TROUBLESHOOTING S-9
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated quickly
Entry of exhaust gas into oil due to internal wear
Clogging of lubrication passage
Defective combustion
Causes
Improper fuel used
Operation under excessive load
Oil change interval is too long
Clogged turbocharger lubrication drain tube

Defective seal at turbocharger turbine end
Clogged breather, breather tube

Worn valve (stem, guide, seal)
Defective oil filter safety valve

Too much engine oil added
Exhaust smoke is black

Clogged oil cooler
Clogged oil filter
Questions

Non-specified oil is being used
Oil level is above H level on gauge
When oil filter is inspected, metal particles are found
When exhaust pipe is removed, inside is found to be dirty with oil
Even when engine oil temperature rises, oil filter warning lamp lights up (machines equipped with warning lamp)
Check items
Engine oil temperature rises quickly

Black
Excessive
Amount of blow-by gas
None
Inspect turbocharger lubrication drain tube directly
Troubleshooting S-7
Troubleshooting
Excessive play of turbocharger shaft

Inspect breather element directly
Carry out
Inspect oil cooler directly

Inspect oil filter directly
Inspect safety valve directly
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
20-1176 HD465-7, HD605-7

(10)
TROUBLESHOOTING S-10
S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive
Leakage of fuel
Defective condition of fuel injection
Defective HPI sensor Causes

Leakage of fuel inside head cover


Defective fuel pump
Defective injector
Questions
More than for other machines of same model

Condition of fuel consumption Gradually increased
Suddenly increased
There is external leakage of fuel from engine
Engine oil level rises and smells of diesel fuel
Check items
Black
Exhaust smoke color
White
Inspect inside of head cover directly

Troubleshooting

Abnormality in fuel rail pressure sensor system is indicated (*1)
Abnormality in timing rail pressure sensor system is indicated (*1)
When flow of return fuel is checked visually, it is found to be low
Inspect sensor directly (Output voltage)
Replace
Replace
Replace
Replace
Replace
Replace
Replace
(*1) If an failure code of the fuel rail pressure sensor system or timing rail pressure sensor
Correct
Clean
Clean
system is displayed, carry out the troubleshooting in "EA mode". Remedy
HD465-7, HD605-7 20-1177

(10)
S-11 Oil is in coolant, or water spurts back, or coolant level goes down
General causes why oil is in coolant
Internal leakage in lubrication system
Internal leakage in cooling system
Causes
Broken power train oil cooler (troubleshooting for machine)

Damaged cylinder liner O-ring, holes caused by pitting
Insufficient protrusion of cylinder liner
Broken cylinder head, head gasket
Internal cracks in cylinder block
Broken oil cooler core, O-ring

Broken water pump seal
Questions
Suddenly increased
Oil level
Gradually increased
Hard water is being used as coolant (or corrosion resistor valve is closed)
Excessive air bubbles inside radiator, spurts back
Check items
Engine oil level has risen, oil is cloudy white

Hydraulic oil, transmission oil on machine side is cloudy white
When hydraulic oil, transmission oil on machine side is drained, water is found
Troubleshooting
Carry out pressure-tightness test of cylinder head

Inspect cylinder block, liner directly
Inspect cylinder liner directly
Carry out pressure-tightness test of oil cooler
Inspect water pump directly
Replace
Replace
Replace
Replace
Replace
Replace
Remedy Replace
20-1178 HD465-7, HD605-7

(10)
S-12 Oil pressure warning lamp lights up (drop in oil pressure)

General causes why oil pressure warning lamp lights up
Leakage, clogging, wear of lubricating system
Defective oil pressure control
Improper selection of fuel (insufficient viscosity) Causes
Deterioration of oil due to overheating
Clogged, broken oil pump suction pipe

Broken oil pump suction pipe brazing
Leaking, crushed hydraulic piping

Clogged oil pan suction strainer
Defective oil pump relief valve
Defective oil pressure sensor

Defective oil level sensor
Worn crankshaft journal
Lack of oil in oil pan
Defective oil pump
Clogged oil cooler
Coolant, fuel in oil

Clogged oil filter
Questions
Non-specified oil is being used

Engine oil pressure warning lamp lights up
Lights up at low idle
Condition when oil pressure warning lamp Lights up at low, high idle
lights up. Lights up on slopes
Sometimes lights up
Oil level warning lamp lights up (machines equipped with warning lamp)
Check items
There is crushing, external leakage from hydraulic piping

Oil level in oil pan is low
Oil is cloudy white or smells of diesel oil
When oil is drained, metal particles are found
When oil filter is inspected, metal particles are found

Carry out Troubleshooting
Inspect suction strainer, pipe directly

Troubleshooting
Oil pump rotation is heavy, there is play

Inspect relief valve, regulator valve directly
When engine oil level sensor is replaced, oil pressure warning lamp goes out
(machines equipped with oil level sensor)
S-13
When oil pressure is measured, it is found to be normal

Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
Add
HD465-7, HD605-7 20-1179

(10)
S-13 Oil level rises

General causes why oil level rises
Coolant in oil (milky white)
Fuel in oil (diluted, and smells of diesel fuel)
Entry of coolant or oil from other component Causes
Clogged water pump drain hole (breather hole), defective seal
Defective auxiliary equipment (pump, compressor) seal

Defective cylinder head injector sleeve
Broken, broken rear oil seal face

Broken oil cooler core, O-ring
Cracks inside cylinder block
Defective thermostat seal

Defective fuel pump seal
Questions

Fuel must be added more frequently
Engine oil smells of diesel fuel
There is oil in coolant (*1)
When engine is first started, drops of water come from muffler
When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles
appear, or coolant (*1) spurts back
Check items
Exhaust smoke is white

Water pump drain hole (breather hole) is clogged
When water pump drain hole (breather hole) is cleaned, coolant comes out
Oil level goes down in clutch or damper chamber
Oil level goes down in hydraulic tank

Troubleshooting
Inspect rear oil seal directly

Carry out pressure-tightness test of oil cooler
Inspect water pump directly
Inspect thermostat directly
Inspect injector directly
Inspect pump auxiliary equipment (pump, compressor) directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
(*1) If there is oil in coolant, carry out Troubleshooting S-11.
20-1180 HD465-7, HD605-7

(10)
S-14 Coolant temperature becomes too high (overheating)

General causes why coolant temperature becomes too high
Lack of cooling air (deformation, damage of fan)
Drop in heat dissipation efficiency
Rise in oil temperature in power train Causes
(troubleshooting for machine)
Rise in power train oil temperature (troubleshooting for

Defective radiator cap (pressure valve)
Defective coolant temperature gauge

Defective operation of thermostat

Fan belt slipping, worn fan pulley
Clogged, crushed radiator fins
Cracks inside cylinder block
Clogged, broken oil cooler
Clogged radiator core
Broken water pump

Lack of coolant
machine)
Questions
Suddenly overheated
Condition of overheating
Always tends to overheat
Rises quickly
Coolant temperature gauge
Does not go down from red range
Radiator coolant level warning lamp lights up (machines equipped with warning lamp)
Engine oil level has risen, oil is cloudy white
Cloudy white oil is floating on coolant
Excessive air bubbles inside radiator, coolant spurts back
When light bulb is held behind radiator, no light passes through
Radiator shroud, inside of underguard are clogged with dirt or mud
Check items
Coolant is leaking because of cracks in hose or loose clamps

When belt tension is inspected, it is found to be loose
Fan belt whines under sudden load
Coolant flows out from overflow hose
Power train oil temperature enters red range faster than engine coolant temperature
When compression pressure is measured, it is found to be low Carry out troubleshooting of machine
Inspect oil cooler directly
Troubleshooting
Inspect radiator core directly

When temperature difference between top and bottom radiator tanks is measured, it is found to
be slight
Carry out function test on radiator cap (cracking pressure)
When temperature difference between top and bottom radiator tanks is measured, it is found to
be excessive
Carry out function test on thermostat (cracking temperature)
When coolant temperature is measured, it is found to be normal
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Add
HD465-7, HD605-7 20-1181

(10)
S-15 Abnormal noise is made

General causes why abnormal noise is made
Abnormality due to defective parts
Abnormal combustion noise
Air sucked in from intake system Causes
Air leakage from auxiliary equipment (pump, compressor)

Broken dynamic valve system (valve, rocker arm, etc.)
Defect inside muffler (dividing board out of position)

Leakage of air between turbocharger and head
Seized turbocharger, internal interference (*1)
Excessive wear of piston ring, cylinder liner
Deformed cooling fan, fan belt interference

Defective adjustment of valve clearance
Missing, seized gear bushing

Improper gear train backlash
Seized crankshaft bearing
Defective injector
Questions
Gradually occurred
Condition of abnormal noise
Suddenly occurred
Seal on injection pump has come off
Metal particles are found in oil filter
Leakage of air between turbocharger and head, loose clamp
Vibrating noise is heard from around muffler
Check items
Black
Engine pickup is poor and combustion is abnormal
Abnormal noise is loud when accelerating engine

Troubleshooting
When muffler is removed, abnormal noise disappears

Inspect crankshaft bearing directly
Inspect front gear and rear gear directly
Inspect cooling fan, belt directly
When temperature of exhaust gas of each cylinder is measured, there are some cylinders that are low
Inspect piping of pump auxiliary equipment (pump, compressor, etc.) directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Remedy
(*1) Judge if the noise is an internal noise or an external noise.
20-1182 HD465-7, HD605-7

(10)
S-16 Vibration is excessive

a If there is abnormal noise together with the vibration,
carry out Troubleshooting S-15 also.
General causes why vibration is excessive

Defective parts (abnormal wear, breakage)
Improper alignment between engine and chassis Causes
Defective dynamic valve system (valve, rocker arm, etc. stuck)

Abnormal combustion
Internal damage in clutch chamber or damper chamber

Loose engine mounting bolts, broken cushion
Worn front support spigot joint portion
Worn main bearing, connecting rod
(troubleshooting for machine)

Improper gear train backlash
Defective vibration damper
Worn cam bushing
Clogged injector
Questions
Suddenly increased
Condition of vibration
Gradually increased
Metal particles are found in oil filter
Metal particles are found when oil is drained
Check items
Oil pressure is low at low idle

Vibration occurs at mid-range speed
Vibration follows engine speed
Exhaust smoke is black

Inspect main bearing, connecting rod directly
Troubleshooting
Inspect cam bushing directly

Inspect front gear train and rear gear train directly
Inspect vibration damper directly
Injection pump test shows that injection amount is incorrect
Inspect front support spigot joint directly
Inspect engine mounting bolts, cushions directly
Inspect clutch chamber or damper chamber directly (troubleshooting for machine)
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Remedy
HD465-7, HD605-7 20-1183

(10)
TROUBLESHOOTING OF
ELECTRICAL SYSTEM (E-MODE)
Electrical system diagram related to emergency steering control ............................................................. 20-1202

Information in troubleshooting table .......................................................................................................... 20-1203
E-1 Emergency steering system does not operate ................................................................................. 20-1205
HD465-7, HD605-7 20-1201

(11)
ELECTRICAL SYSTEM DIAGRAM RELATED TO
TROUBLESHOOTING EMERGENCY STEERING CONTROL
ELECTRICAL SYSTEM DIAGRAM RELATED TO EMERGENCY STEERING CONTROL

20-1202 HD465-7, HD605-7

(11)

Trouble Trouble in machine
Related
Information related to detected trouble or troubleshooting
information

Remarks on judgment
1
Disconnection
Ground fault
Harness which is not connected to chassis ground circuit is in contact
2
with chassis ground circuit.
Possible causes Short circuit
Possible causes of trouble
and standard Independent harnesses are in contact with each other abnormally.
(Given numbers are refer-
value in normal 3
ence numbers, which do
state <Precautions for troubleshooting>
not indicate priority)
1) Method of indicating connector No. and handling of T-adapter
4 connector and insert T-adapters in both male side and female side.
If connector No. has marks of "male" and "female", disconnect con-
nector and connect T-adapter to only male side or female side.
Connect positive (+) lead and negative () lead of tester as explained
below for troubleshooting, unless otherwise specified.
5 Connect positive (+) lead to pin No. or harness entered on front side.
side.
HD465-7, HD605-7 20-1203

(11)

20-1204 HD465-7, HD605-7

(11)
TROUBLESHOOTING E-1
E-1 EMERGENCY STEERING SYSTEM DOES NOT OPERATE
1) When emergency steering switch is pressed, emergency steering system does not operate.
Trouble
2) Automatic emergency steering system does not operate.
aSee Operation and Maintenance Manual, Operation, Testing and adjusting before starting engine, In-
Related spection of emergency steering and Inspection of automatic emergency steering.
information When parking brake is released, voltage is generated at pin H01 (2). When flow on flow switch is lost
and flow switch is turned ON, voltage is generated at pin H01 (1).

Defective fuse BT2-(26) or If fuse is broken, circuit probably has ground fault. (Carry out trouble-
1
BT3-(16) shooting for cause 8.)
aPrepare with starting switch OFF, then carry out troubleshooting with-
out turning starting switch ON.
Defective emergency Terminals of switch Emergency steering switch Resistance
2
steering switch
Between input terminal ON Max. 1 z
output terminal OFF Min. 1 Mz
1) Turn starting switch OFF and disconnect parking brake connector
PSW (or HTA).
2) Start engine and apply retarder brake, then carry out troubleshooting.
Defective parking brake PSW (male) Parking brake switch Resistance
3
switch
When parking brake is released Max. 1 z
Between (1) (2) When parking brake is operated
Min. 1 Mz
(applied)
aPrepare with starting switch OFF, then turn starting switch ON and car-
ry out troubleshooting.
Between inlet terminal from fuse BT2 (26)
Voltage 20 30V
and standard aEven if starting switch is turned ON, parking brake is not released until
value in normal parking brake switch is turned ON (operated) and OFF once. (While
state parking brake is released, contacts of parking brake should be connect-
ed to each other.)
1) Start engine, charge accumulator, apply retarder brake, and stop en-
Defective emergency gine.
steering timer
3) Turn parking brake switch OFF (Release).
Between inlet terminal from flow switch chas-
Voltage 20 30V
sis ground
Between emergency steering relay drive termi-
Voltage 20 30V
nal chassis ground
Between switch ground terminal chassis
Resistance Max. 1 z
ground (GND 2)
2) Turn emergency steering switch ON and carry out troubleshooting.
Between motor (+) terminal chassis ground Voltage 20 30V
5 Defective starting motor
Between motor (-) terminal chassis ground Resistance Max. 1 z
HD465-7, HD605-7 20-1205

(11)
TROUBLESHOOTING E-1

2) Turn emergency steering switch ON and carry out troubleshooting.
Between emergency steering relay terminal B
Voltage 20 30V
chassis ground
Between emergency steering relay terminal M
Defective emergency Voltage 20 30V
chassis ground
6 steering relay (Both are
same) Between emergency steering relay drive termi-
Voltage 20 30V
nal chassis ground
Between emergency steering relay ground ter-
Resistance Max. 1 z
minal chassis ground
Wiring harness between emergency steering re-
Resistance Max. 1 z
lay terminal M motor (+) terminal
Resistance Max. 1 z
lay drive terminal timer drive terminal
Wiring harness between fuse BT2 (26) timer
Resistance Max. 1 z
Disconnection in wiring power supply input terminal
Possible causes
harness (Disconnection in Wiring harness between fuse BT3 (16) PSW
and standard 7 Resistance Max. 1 z
wiring or defective contact (female) (1)
value in normal
in connector)
state Wiring harness between PSW (female) (2)
Resistance Max. 1 z
CJN H01 (female) (2)
Wiring harness between H01 (female) (1) timer
Resistance Max. 1 z
inlet terminal
Resistance Max. 1 z
lays (All of 4)
Resistance Max. 1 z
lay (-) terminal CJK chassis ground
lay terminal M motor (+) terminal
lay drive terminal timer drive terminal
Ground fault in wiring
Wiring harness between fuse BT2 (26) timer
8 harness (Short circuit with Resistance Min. 1 Mz
power supply input terminal
GND circuit)
Wiring harness between fuse BT3 (16) PSW
(female) (1)
Wiring harness between PSW (female) (2)
CJN H01 (female) (2)
Wiring harness between H01 (female) (1) timer
inlet terminal
a If "the emergency steering system operates by itself (while the switch is not turned ON)", check the following
possible causes.
1) The emergency steering relay is fixed to the ON position because of some vibration. (Replace the
emergency steering relay.)
2) The voltage at the (+) terminal of the emergency steering relay is 20 30 V. (This terminal should be
grounded.)
3) The wiring on the M side of the emergency steering relay is in contact with the wiring on the B side.
(Open the battery box and check the wiring.)
4) The parking brake oil pressure switch is stuck. (Replace the parking brake oil pressure switch.)
5) The steering flow switch is stuck. (Replace the steering flow switch.)
20-1206 HD465-7, HD605-7

(11)
TROUBLESHOOTING E-1
a How to distinguish the emergency steering relays and the ordinary battery relay.
When the battery box is opened, the 2 relays on the left side (on the front side of the machine) are the emer-
gency steering relays.
HD465-7, HD605-7 20-1207

(11)
TROUBLESHOOTING OF ABS CONTROLLER
SYSTEM (ABS MODE) (IF EQUIPPED)
Electrical system diagram related ABS control ........................................................................................ 20-1252
Information in troubleshooting table .......................................................................................................... 20-1254
Phenomenon code table ........................................................................................................................... 20-1255
[D1E5KZ] ABS cut relay: Disconnection or short circuit (KZ)................................................................ 20-1256
[DBC0KK] ABS controller: Supply voltage reduction (KK) ..................................................................... 20-1258
[DBC1KK] ABS controller main power line: Supply voltage reduction (KK) ........................................... 20-1259
[DBC2KK] ABS controller load power line: Supply voltage reduction (KK) ............................................ 20-1260
[DBC3KK] ABS controller battery direct power supply: Supply voltage reduction (KK) ......................... 20-1262
[DBC9KM] ABS controller wire wiring harness: Setting operation error (KM) ........................................ 20-1263
[DBCSKR] ABS controller S-NET communication: Defective communication (KR) ............................... 20-1264
[DBCSMA] ABS controller S-NET communication: Defective communication (MA)............................ 20-1264-1
[DDD9KA] ABS system switch: Disconnection (KA) .............................................................................. 20-1265
[DDD9KB] ABS system switch: Short circuit (KB) .................................................................................. 20-1266
[DHU6KX] ABS control valve pressure sensor front wheel right (FR):
Outside input signal range (KX) ....................................................................................... 20-1268
[DHU7KX] ABS control valve pressure sensor front wheel left (FL):
[DHU8KX] ABS control valve pressure sensor rear wheel right (RR):
[DHU9KX] ABS control valve pressure sensor rear wheel left (RL):
[dk11KX] Accelerator sensor: Outside input signal range (KX)............................................................ 20-1276
[DLF6KA] Wheel speed sensor front wheel right (FR): Disconnection (KA) ......................................... 20-1278
[DLF7KA] Wheel speed sensor front wheel left (FL): Disconnection (KA) ............................................ 20-1280
[dLF8KA] Wheel speed sensor rear wheel right (RR): Disconnection (KA).......................................... 20-1282
[dLF9KA] Wheel speed sensor rear wheel left (RL): Disconnection (KA)............................................. 20-1284
[DWNDKZ] ABS cut valve (F): Disconnection or short circuit (KZ) ......................................................... 20-1286
[DWNDMA] ABS cut valve (F): Malfunction (MA) .................................................................................... 20-1288
[DWNEKZ] ABS cut valve (R): Disconnection or short circuit (KZ) ......................................................... 20-1290
[DWNEMA] ABS cut valve (R): Malfunction (MA) .................................................................................... 20-1292
[DX21KA] ABS control valve front wheel right (FR): Disconnection (KA).............................................. 20-1293
[DX21KB] ABS control valve front wheel right (FR): Short circuit (KB) ................................................. 20-1294
[DX21KY] ABS control valve front wheel right (FR): Short-circuited to power supply (KY) ................... 20-1295
[DX21MA] ABS control valve front wheel right (FR): Malfunction (MA) ................................................. 20-1296
[DX22KA] ABS control valve front wheel left (FL): Disconnection (KA)................................................. 20-1297
[DX22KB] ABS control valve front wheel left (FL): Short circuit (KB) .................................................... 20-1298
[DX22KY] ABS control valve front wheel left (FL): Short-circuited to power supply (KY)...................... 20-1299
[DX22MA] ABS control valve front wheel left (FL): Malfunction (MA) .................................................... 20-1300
[DX23KA] ABS control valve rear wheel right (RR): Disconnection (KA) .............................................. 20-1301
[DX23KB] ABS control valve rear wheel right (RR): Short circuit (KB).................................................. 20-1302
[DX23KY] ABS control valve rear wheel right (RR): Short-circuited to power supply (KY) ................... 20-1303
[DX23MA] ABS control valve rear wheel right (RR): Malfunction (MA).................................................. 20-1304
[DX24KA] ABS control valve rear wheel left (RL): Disconnection (KA) ................................................. 20-1305
[DX24KB] ABS control valve rear wheel left (RL): Short circuit (KB)..................................................... 20-1306
[DX24KY] ABS control valve rear wheel left (RL): Short-circuited with power supply (KY)................... 20-1307
[DX24MA] ABS control valve rear wheel left (RL): Malfunction (MA)..................................................... 20-1308
[DX25MA] ABS control valve (front wheel system): Malfunction (MA)................................................... 20-1309
[DX26MA] ABS control valve (rear wheel system): Malfunction (MA) ................................................... 20-1310
HD465-7, HD605-7 20-1251

(16)
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED ABS CONTROL
ELECTRICAL SYSTEM DIAGRAM RELATED ABS CONTROL
20-1252 HD465-7, HD605-7

(12)
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED ABS CONTROL
HD465-7, HD605-7 20-1253

(12)

panel panel panel
Contents of trouble Contents of trouble detected by machine monitor or controller
Action of machine Action taken by controller to protect system or devices when machine monitor or controller detects trou-
monitor or controller ble
Problem that Problem that appears on machine as result of action taken by machine monitor or controller
appears on machine (shown above)
Related information Information related to the detected trouble or troubleshooting

Remarks on judgment
1
<Troubles in wiring harness>
Disconnection
Connector is connected imperfectly or wiring harness is broken.
Ground fault
Wiring harness which is not connected to chassis ground circuit is in
2 contact with chassis ground circuit.
Hot short
Wiring harness, which is not connected to power source (24 V) cir-
cuit, is in contact with power source (24 V) circuit.
Short circuit
Independent wiring harnesses are in contact with each other abnor-
Possible causes Possible causes of troubles mally.
3
in normal state ence numbers, which do not <Precautions for troubleshooting>
indicate priority.) (1) Method of indicating connector No. and handling of T-adapter
Insert or connect T-adapter as explained below for troubleshoot-
ing, unless otherwise specified.
if connector No. has no marks of "male" and "female", disconnect
4 side.
If connector No. has marks of "male" and "female", disconnect
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (-) lead of tester as ex-
Connect positive (+) lead to pin No. or wiring harness entered on
5
front side.
Connect negative (-) lead to pin No. or wiring harness entered on
rear side side.
20-1254 HD465-7, HD605-7

(12)
Related circuit diagram

Connector No.: Indicates (Model - Number of pins) and (Color).

Phenomenon Contents
code
KA Disconnection is wiring
KB Short circuit
KK Supply voltage reduction
KM Operation or setting error
KR Defective communication
KX Outside input signal range
KY Hot short (short-circuit with power source)
KZ Disconnection or short circuit
MA Malfunction
HD465-7, HD605-7 20-1255

(12)
TROUBLESHOOTING [D1E5KZ]
[D1E5KZ] ABS CUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ)
Action code Failure code Controller code ABS cut relay:

Trouble
E03 D1E5KZ ABS Disconnection or short circuit on ABS cut relay (KZ)
Excessive current is conducted or no current is conducted as output is generated to ABS cut relay cir-
Contents of trouble cuit.
Current is conducted after the output is turned off.
Action of controller Stops ABS control.
Problem that ABS doesn't work.
appears on machine Usual brake is operable.
Related information

1) Turn off starting switch.
2) Disconnect connectors ABS1 and RABS.
ness
1 Wiring harness between ABS1 (female) (14)
RABS (female) (1)
contact)
Between chassis ground wiring harness
Resistance Max. 1 z
RABS (female) (2)
2
ness
Wiring harness between ABS1 (female) (14),
Possible causes Resistance Min. 1 Mz
RABS (female) (1) chassis ground
and standard value
in normal state 1) Turn off starting switch.
3 Hot short on wiring harness 4) Connect the connector.
5) Turn on starting switch.
Voltage Max. 1 V
RABS (female) (1) chassis ground
4 Defective ABS cut relay Replacing ABS cut relay restores the normal state.
2) Disconnect connector ABS1.
5 Defective ABS controller 3) Connect T-adapter.
Wiring harness between ABS1 (female) (14) 250
Resistance
chassis ground 350 z
20-1256 HD465-7, HD605-7

(12)
TROUBLESHOOTING [D1E5KZ]
HD465-7, HD605-7 20-1257

(12)
TROUBLESHOOTING [DBC0KK]
[DBC0KK] ABS CONTROLLER: SUPPLY VOLTAGE REDUCTION (KK)
Action code Failure code Controller code ABS controller: Supply voltage reduction in main and direct sup-
Trouble
E03 DBC0KK ABS ply voltage circuits (KK)
Contents of trouble Both the main supply voltage and direct supply voltage circuits went below 17 V.
Related information

Disconnection in wiring har- 2) Disconnect connector ABS1.
1
contact) Wiring harness between ABS1 (female) (8),
Resistance Max. 1 z
(16) chassis ground
Defective battery or defec- Battery voltage shall be 24 V minimum and specific gravity shall be
2
Possible causes tive charging 1.26.
and standard value
in normal state
3 Defective ABS controller
Wiring harness between ABS1 (female) (7)
Voltage 20 30 V
ABS1 (female) (8), (16)
Voltage 20 30 V
(17) ABS1 (female) (8), (16)
20-1258 HD465-7, HD605-7

(12)
[DBC1KK] ABS CONTROLLER MAIN POWER LINE: SUPPLY VOLTAGE REDUCTION

(KK)

Trouble ABS controller main power line: Supply voltage reduction (KK)
E03 DBC1KK ABS
Difference of voltage between the main supply voltage circuit and direct supply voltage circuit became
Contents of trouble
5 V or greater.
Related information

in normal state (Disconnection or defective 5) Turn on starting switch.
contact)
Voltage 20 30 V
(17) ABS1 (female) (8), (16)
Related electric circuit diagram
HD465-7, HD605-7 20-1259

(12)
[DBC2KK] ABS CONTROLLER LOAD POWER LINE: SUPPLY VOLTAGE REDUCTION

(KK)
Action code Failure code Controller code ABS controller load power line:
Trouble
E03 DBC2KK ABS Voltage reduction in solenoid supply voltage (KK)
Solenoid supply voltage went 17 V or below while controller supply voltage circuit was operating nor-
Contents of trouble
mally.
Related information

1 Defective ABS cut relay Replace it with other relay to restore normal state.
ness 1 3) Connect T-adapter.
2 4) Turn on starting switch.
contact) Wiring harness between RABS (female) (5)
Voltage 20 30 V
chassis ground
Disconnection in wiring har- 2) Disconnect connectors RABS and ABS1.
Possible causes ness 2 3) Connect T-adapter.
in normal state Wiring harness between RABS (female) (3)
ABS1 (female) (9), (17)
2) Disconnect connectors ABS1 and ABS2.
4 Defective ABS controller 5) Turn on starting switch.
Voltage 20 30 V
ABS1 (female) (8), (16)
Voltage 20 30 V
ABS1 (female) (8), (16)
20-1260 HD465-7, HD605-7

(12)
HD465-7, HD605-7 20-1261

(12)
[DBC3KK] ABS CONTROLLER BATTERY DIRECT POWER SUPPLY: SUPPLY

VOLTAGE REDUCTION (KK)
Action code Failure code Controller code ABS controller battery direct power supply:
Trouble
E03 DBC3KK ABS Supply voltage reduction (KK)
Contents of trouble Voltage of battery direct power supply circuit went 5 V or below.
Action of controller Continues ABS control.
Problem that
Remains unchanged.
appears on machine
Related information

1
(Disconnection or defective 4) Turn on starting switch.
Possible causes contact) Wiring harness between ABS1 (female) (7)
Voltage 20 30 V
and standard value ABS1 (female) (8), (16)
in normal state
2) Disconnect connectors ABS1 and ABS2.
2 Defective ABS controller 4) Turn on starting switch.
Voltage 20 30 V
ABS1 (female) (8), (16)
20-1262 HD465-7, HD605-7

(12)
TROUBLESHOOTING [DBC9KM]
[DBC9KM] ABS CONTROLLER WIRE WIRING HARNESS: SETTING OPERATION

ERROR (KM)

Trouble ABS controller wiring harness: Setting operation error (KM)
E03 DBC9KM ABS
Connector-check signal to be entered at turning on of starting switch does not match the internal set-
Contents of trouble
ting of controller.
Related information

Wrong connection of con- 1) Turn off starting switch.
1
Possible causes troller connector Connectors ABS3A and ABS5A are appropriately installed.
and standard value 1) Turn off starting switch.
in normal state Disconnection in wiring har- 2) Disconnect connector ABS5A.
2
Wiring harness between ABS5A (female) (1)
chassis ground
HD465-7, HD605-7 20-1263

(12)
TROUBLESHOOTING [DBCSKR]
[DBCSKR] ABS CONTROLLER S-NET COMMUNICATION: DEFECTIVE

COMMUNICATION (KR)
Action code Failure code Controller code ABS controller S-NET communication:
Trouble
E03 DBCSKR ABS Communication failure (KR)
Contents of trouble Input of communication information from monitor to ABS controller is unavailable.
Related information

1
contact)
Possible causes Wiring harness between ABS4 (female) (6),
Voltage 69V
and standard value (12) chassis ground
2 Defective ABS controller 4) Connect the connector.
Voltage 69V
(12) chassis ground
20-1264 HD465-7, HD605-7

(12)
TROUBLESHOOTING [DBCSMA]
[DBCSMA] ABS CONTROLLER S-NET COMMUNICATION: DEFECTIVE

COMMUNICATION (MA)
Action code Failure code Controller code ABS controller S-NET communication:
Trouble
Not set DBCSMA ABS Communication failure (MA)
Contents of trouble Input of communication information from monitor to ABS controller is unavailable.
Related information

1
contact)
Voltage 69V
and standard value (12) chassis ground
Voltage 69V
(12) chassis ground
HD465-7, HD605-7 20-1264-1

(16)
TROUBLESHOOTING [DDD9KA]
[DDD9KA] ABS SYSTEM SWITCH: DISCONNECTION (KA)

Trouble ABS system switch: Disconnection (KA)
E03 DDD9KA ABS
Contents of trouble ON-input and OFF-input of ABS system switch were turned off.
Related information

2) Disconnect connectors ABS and DPC2B.
1 Hot short on wiring harness 3) Connect T-adapter.
Resistance Max. 1 z
ABS (female) (3)
2) Replace ABS system switch with a normal one.
Defective ABS system
Possible causes 2 Normal state System switch is nor-
switch mal
and standard value After replacing ABS system was not restored
in normal state switch with a normal one: Normal state System switch is defec-
was restored tive
Wiring harness be- Turn on ABS system
Voltage 20 30 V
tween DPC2B (fe- switch
male) (2) chassis Turn off ABS system
switch
HD465-7, HD605-7 20-1265

(12)
TROUBLESHOOTING [DDD9KB]
[DDD9KB] ABS SYSTEM SWITCH: SHORT CIRCUIT (KB)

Trouble ABS system switch: Short circuit (KB)
E03 DDD9KB ABS
Contents of trouble ON-input and OFF-input of ABS system switch were turned on.
Related information

2) Disconnect connectors ABS and DPC2B.
1
ness
ABS (female) (3)
2) Replace ABS system switch with a normal one.
Defective ABS system
Possible causes 2 Normal state System switch is nor-
switch mal
and standard value After replacing ABS system was not restored
in normal state switch with a normal one: Normal state System switch is defec-
was restored tive
Wiring harness be- Turn on ABS system
Voltage 20 30 V
tween DPC2B (fe- switch
male) (2) chassis Turn off ABS system
switch
20-1266 HD465-7, HD605-7

(12)
[DHU6KX] ABS CONTROL VALVE PRESSURE SENSOR FRONT WHEEL RIGHT (FR):
OUTSIDE INPUT SIGNAL RANGE (KX)
Action code Failure code Controller code ABS control valve pressure sensor front wheel right (FR):
Trouble Outside input signal range (KX)
E03 DHU6KX ABS
Input voltage to ABS control valve pressure sensor (FR) signal circuit went 0.3 V or below or 4.7 V or
Contents of trouble
above.
Related information

2) Disconnect connectors ABS2, ABS3A and BPFR.
Disconnection in wiring har- Wiring harness between ABS3A (female) (16)
1 BPFR (female) (1)
contact) Wiring harness between ABS3A (female) (9)
Resistance Max. 1 z
BPFR (female) (3)
Resistance Max. 1 z
BPFR (female) (2)
2) Disconnect connectors ABS3A and BPFR.
2
ness
Possible causes Wiring harness between ABS3A (female) (9),
and standard value BPFR (female) (3) chassis ground
2) Disconnect connectors ABS3A and BPFR.
Wiring harness between ABS3A (female) (9),
Voltage Max. 4.7 V
BPFR (female) (3) chassis ground
Replacing pressure sensor (Front wheel right: BPFR) with (Front wheel
4 Defective sensor
left: BPFL) restores the normal state.
2) Disconnect connector ABS3A.
5 Defective ABS control 4) Connect the connector.
Across terminals between ABS3A (female) (9)
Voltage 0.3 4.7 V
ABS3A (female) (16)
20-1268 HD465-7, HD605-7

(12)
HD465-7, HD605-7 20-1269

(12)
[DHU7KX] ABS CONTROL VALVE PRESSURE SENSOR FRONT WHEEL LEFT (FL):
Action code Failure code Controller code ABS control valve pressure sensor front wheel left (FL):
Trouble
E03 DHU7KX ABS Outside input signal range (KX)
Input voltage to ABS control valve pressure sensor (FL) signal circuit went 0.3 V or below or 4.7 V or
Contents of trouble
above.
Related information

1) Turn off the starting switch.
2) Disconnect connectors ABS2, ABS3 and BPFL.
Disconnection in wiring har- Wiring harness between ABS3A (female) (16)
1 BPFL (female) (1)
Resistance Max. 1 z
BPFL (female) (3)
Resistance Max. 1 z
BPFL (female) (2)
1) Turn off the starting switch.
2) Disconnect connectors ABS3 and BPFL.
2
ness
Possible causes Wiring harness between ABS3A (female) (10),
and standard value BPFL (female) (3) chassis ground
2) Disconnect connectors ABS3A and BPFL.
Voltage Max. 4.7 V
BPFL (female) (3) chassis ground
Replacing pressure sensor (Front wheel left: BPFL) with (Front wheel
4 Defective pressure sensor
right: BPFR) restores the normal state.
5 Defective ABS control 4) Connect the connector.
Across terminals between ABS3A (female)
Voltage 0.3 4.7 V
(10) ABS3A (female) (16)
20-1270 HD465-7, HD605-7

(12)
HD465-7, HD605-7 20-1271

(12)
[DHU8KX] ABS CONTROL VALVE PRESSURE SENSOR REAR WHEEL RIGHT (RR):
Action code Failure code Controller code ABS control valve pressure sensor rear wheel right (RR):
Trouble
Input voltage to ABS control valve pressure sensor (RR) signal circuit went 0.5 V or below or 4.7 V or
Contents of trouble
above.
Related information

2) Disconnect connectors ABS1, ABS3A and BPRR.
ness 1 Wiring harness between ABS3A (female) (16)
Resistance Max. 1 z
1 (Pressure sensor circuit) BPRR (female) (1)
(Disconnection or defective Wiring harness between ABS3A (female) (19)
BPRR (female) (3)
Resistance Max. 1 z
BPRR (female) (2)
Ground fault in wiring har- 2) Disconnect connectors ABS3A and BPRR.
2 ness 3) Connect T-adapter.
(Pressure sensor circuit) Wiring harness between ABS3A (female) (19),
BPRR (female) (3) chassis ground
2) Disconnect connectors ABS3A and BPRR.
Hot short on wiring harness 4) Connect the connector.
3
(Pressure sensor circuit) 5) Turn on starting switch.
Possible causes Voltage Max. 4.7 V
BPRR (female) (3) chassis ground
and standard value
2) Disconnect connectors ABS5A and S01F.
ness 2
4 (Service brake switch circuit) Wiring harness between ABS5A (female) (6)
Resistance Max. 1 z
(Disconnection or defective S01F(female) (1)
contact)
Wiring harness between S01M (male) (2)
Resistance Max. 1 z
S01F (female) (2)
2) Disconnect connectors ABS5A and BRC5A.
ness 3
5 (Retarder switch circuit) Wiring harness between ABS5A (female) (5)
Resistance Max. 1 z
(Disconnection or defective BRC5A (F) (female) (4)
contact)
Wiring harness between BRC5A (M) (male) (4)
Resistance Max. 1 z
BRC5A (F) (female) (4)
Replacing pressure sensor (Rear wheel right: BPRR) with (Rear wheel
left: BPRL) restores the normal state.
Voltage 0.5 4.7 V
20-1272 HD465-7, HD605-7

(12)
HD465-7, HD605-7 20-1273

(12)
[DHU9KX] ABS CONTROL VALVE PRESSURE SENSOR REAR WHEEL LEFT (RL):
Action code Failure code Controller code ABS control valve pressure sensor rear wheel left (RL):
Trouble
Input voltage to ABS control valve pressure sensor (RL) signal circuit went 0.5 V or below or 4.7 V or
Contents of trouble
above.
Related information

2) Disconnect connectors ABS1, ABS3A and BPRL.
ness 1 Wiring harness between ABS3A (female) (16)
Resistance Max. 1 z
1 (Pressure sensor circuit) BPRL (female) (1)
(Disconnection or defective Wiring harness between ABS3A (female) (20)
BPRL (female) (3)
Resistance Max. 1 z
BPRL (female) (2)
Ground fault in wiring har- 2) Disconnect connectors ABS3A and BPRL.
2 ness 3) Connect T-adapter.
(Pressure sensor circuit) Wiring harness between ABS3A (female) (20),
BPRL (female) (3) chassis ground
2) Disconnect connectors ABS3A and BPRL.
Hot short on wiring harness 4) Connect the connector.
3
(Pressure sensor circuit) 5) Turn on starting switch.
Possible causes Voltage Max. 4.7 V
BPRL (female) (3) chassis ground
and standard value
2) Disconnect connectors ABS5A and S01F.
ness 2
4 (Service brake switch circuit) Wiring harness between ABS5A (female) (6)
Resistance Max. 1 z
(Disconnection or defective S01F(female) (1)
contact)
Wiring harness between S01M (male) (2)
Resistance Max. 1 z
S01F (female) (2)
2) Disconnect connectors ABS5A and BRC5A.
ness 3
5 (Retarder switch circuit) Wiring harness between ABS5A (female) (5)
Resistance Max. 1 z
(Disconnection or defective BRC5A (F) (female) (4)
contact)
Wiring harness between BRC5A (M) (male) (4)
Resistance Max. 1 z
BRC5A (F) (female) (4)
Replacing pressure sensor (Rear wheel right: BPRR) with (Rear wheel
left: BPRL) restores the normal state.
Voltage 0.5 4.7 V
20-1274 HD465-7, HD605-7

(12)
HD465-7, HD605-7 20-1275

(12)
[dk11KX] ACCELERATOR SENSOR: OUTSIDE INPUT SIGNAL RANGE (KX)

Trouble Accelerator sensor: Outside input signal range (KX)
E03 dk11KX ABS
Contents of trouble Voltage of accelerator sensor signal circuit went 0.6 V or below or 4.7 V or above.
Related information

2) Disconnect connectors ABS3B and BRC3B.
ness
1 Wiring harness between ABS3B (female) (14)
BRC3B (F) (female) (11)
contact)
Wiring harness between BRC3B (M) (male)
Resistance Max. 1 z
(11) BRC3B (F) (female) (11)
2
ness Wiring harness between ABS3B (female) (14),
BRC3B (F) (female)(11), BRC3B (M) (male) Resistance Min. 1 Mz
Possible causes (11) chassis ground
and standard value
3 Hot short on wiring harness 5) Turn on starting switch.
Wiring harness between ABS3B (female) (14),
BRC3B (F) (female)(11), BRC3B (M) (male) Voltage Max. 4.7 V
(11) chassis ground
4 Defective accelerator sensor Replacing failed accelerator sensor restores the normal state.
2) Disconnect connectors ABS3B and BRC3A.
Across terminals between ABS3B (female)
Voltage 0.6 4.7 V
20-1276 HD465-7, HD605-7

(12)
HD465-7, HD605-7 20-1277

(12)
[DLF6KA] WHEEL SPEED SENSOR FRONT WHEEL RIGHT (FR): DISCONNECTION

(KA)

Trouble Wheel speed sensor front wheel right (FR): Disconnection (KA)
E03 DLF6KA ABS
Contents of trouble Input of pulse signal to wheel speed sensor (FR) signal circuit is unavailable.
Related information

2) Disconnect connector WSFR.
1
sor (FR)
Wiring harness between WSFR (male) (1) 1,150
Resistance
WSFR (male) (2) 1,450 z
2) Disconnect connectors ABS3A and WSFR.
ness
2 Wiring harness between ABS3A (female) (2)
WSFR (female) (1)
contact)
Resistance Max. 1 z
WSFR (female) (2)
1) Turn off starting switch.Connect the connector.Connect the connec-
tor.
Possible causes
and standard value
in normal state Ground fault in wiring har-
3
ness Wiring harness between ABS3A (female) (2),
WSFR (female) (1) chassis ground
Voltage Max. 5 V
2) Disconnect connectors ABS3A.
Across terminals between ABS3A (female) (2) 1,150
Resistance
ABS3A (female) (14) 1,450 z
20-1278 HD465-7, HD605-7

(12)
HD465-7, HD605-7 20-1279

(12)
[DLF7KA] WHEEL SPEED SENSOR FRONT WHEEL LEFT (FL): DISCONNECTION (KA)

Trouble Wheel speed sensor front wheel left (FL): Disconnection (KA)
E03 DLF7KA ABS
Contents of trouble Input of pulse signal to wheel speed sensor (FL) signal circuit is unavailable.
Related information

2) Disconnect connector WSFL.
1
sor (FR)
Wiring harness between WSFL(male) (1) 1,150
Resistance
WSFL (male) (2) 1,450 z
2) Disconnect connectors ABS3A and WSFL.
ness
WSFL (female) (1)
contact)
Resistance Max. 1 z
WSFL (female) (2)
Possible causes 2) Disconnect connectors ABS3A and WSFL.
3 Wiring harness between ABS3A (female) (3),
ness Resistance Min. 1 Mz
WSFL (female) (1) chassis ground
2) Disconnect connectors ABS3A and WSFL.
Voltage Max. 5 V
Across terminals between ABS3A (female) (3) 1,150
Resistance
ABS3A (female) (14) 1,450 z
20-1280 HD465-7, HD605-7

(12)
HD465-7, HD605-7 20-1281

(12)
[dLF8KA] WHEEL SPEED SENSOR REAR WHEEL RIGHT (RR): DISCONNECTION (KA)

Trouble Wheel speed sensor rear wheel right (RR): Disconnection (KA)
E03 dLF8KA ABS
Contents of trouble Input of pulse signal to wheel speed sensor (RR) signal circuit is unavailable.
Related information

2) Disconnect connector WSRR2.
1
sor (FR)
Wiring harness between WSRR2 (male) (1) 1,150
Resistance
WSRR2 (male) (2) 1,450 z
2) Disconnect connectors ABS3A and WSRR2.
ness
WSRR2 (female) (1)
contact)
Resistance Max. 1 z
WSRR2 (female) (2)
Possible causes 2) Disconnect connectors ABS3A and WSRR2.
WSRR2 (female) (1) chassis ground
2) Disconnect connectors ABS3A and WSRR2.
Voltage Max. 5 V
Across terminals between ABS3A (female) 1,150
Resistance
(12) ABS3A (female) (14) 1,450 z
20-1282 HD465-7, HD605-7

(12)
HD465-7, HD605-7 20-1283

(12)
[dLF9KA] WHEEL SPEED SENSOR REAR WHEEL LEFT (RL): DISCONNECTION (KA)

Trouble Wheel speed sensor rear wheel left (RL): Disconnection (KA)
E03 dLF9KA ABS
Contents of trouble Input of pulse signal to wheel speed sensor (RL) signal circuit is unavailable.
Related information

2) Disconnect connector WSRL2.
1
sor (RL)
Wiring harness between WSRL2 (male) (1) 1,150
Resistance
WSRL2 (male) (2) 1,450 z
2) Disconnect connectors ABS3A and WSRL2.
ness
WSRL2 (female) (1)
contact)
Resistance Max. 1 z
WSRL2 (female) (2)
Possible causes 2) Disconnect connectors ABS3A and WSRL2.
WSRL2 (female) (1) chassis ground
2) Disconnect connectors ABS3A and WSRL2.
Voltage Max. 5 V
Across terminals between ABS3A (female) 1,150
Resistance
(13) ABS3A (female) (14) 1,450 z
20-1284 HD465-7, HD605-7

(12)
HD465-7, HD605-7 20-1285

(12)
TROUBLESHOOTING [DWNDKZ]
[DWNDKZ] ABS CUT VALVE (F): DISCONNECTION OR SHORT CIRCUIT (KZ)

Trouble ABS cut valve (F): Disconnection or short circuit (KZ)
E03 DWNDKZ ABS
Excessive current is conducted or no current is conducted as output is generated to ABS cut valve (F)
Contents of trouble circuit.
Action of controller Stops ABS control (front wheels).
Problem that ABS doesn't work (front wheels).
Related information

2) Disconnect connectors ABS1 and CVF.
ness
1 Wiring harness between ABS 1(female) (1)
CVF (female) (1)
contact)
Wiring harness between CVF (female) (2)
Resistance Max. 1 z
chassis ground
2
ness
and standard value CVF (female) (1) chassis ground
in normal state
Voltage Max. 1 V
CVF (female) (1) chassis ground
4 Defective ABS cut valve (F): Replacing ABS cut valve (F) restores the normal state.
Resistance 10 30 z
chassis ground
20-1286 HD465-7, HD605-7

(12)
TROUBLESHOOTING [DWNDKZ]
HD465-7, HD605-7 20-1287

(12)
TROUBLESHOOTING [DWNDMA]
[DWNDMA] ABS CUT VALVE (F): MALFUNCTION (MA)

Trouble ABS cut valve (F): Malfunction (MA)
E03 DWNDMA ABS
Contents of trouble ABS cut valve (F) does not operate normally.
Action of controller Stops ABS control (front wheel).
Related information

Defective ABS cut valve Replacing it with ABS cut valve pressure switch (R) restores the nor-
1
pressure switch (F) mal state.
2 Defective ABS cut valve (F) Replacing ABS cut valve (F) restores the normal state.
Possible causes Disconnection in wiring har- 2) Disconnect connectors ABS5A and CVSF.
and standard value 3 ness 3) Connect T-adapter.
Resistance Max. 1 z
CVSF (female) (1)
2) Disconnect connectors ABS5A and CVSF.
4
ness
CVSF (female) (1) chassis ground
20-1288 HD465-7, HD605-7

(12)
TROUBLESHOOTING [DWNEKZ]
[DWNEKZ] ABS CUT VALVE (R): DISCONNECTION OR SHORT CIRCUIT (KZ)

Trouble ABS cut valve (R): Disconnection or short circuit (KZ)
E03 DWNEKZ ABS
Excessive current is conducted or no current is conducted as output is generated to ABS cut valve (R)
Contents of trouble circuit.
Action of controller Stops ABS control (rear wheels).
Problem that ABS doesn't work (rear wheels).
Related information

2) Disconnect connectors ABS1 and RABS2.
ness
RABS2 (female) (1)
contact)
Wiring harness between RABS2 (female) (2)
Resistance Max. 1 z
chassis ground
2
ness
and standard value RABS2 (female) (1) chassis ground
in normal state
Voltage Max. 1 V
RABS2 (female) (1) chassis ground
4 Defective ABS cut valve (R) Replacing ABS cut valve (R) restores the normal state.
Resistance 10 30z
chassis ground
20-1290 HD465-7, HD605-7

(12)
TROUBLESHOOTING [DWNEKZ]
HD465-7, HD605-7 20-1291

(12)
TROUBLESHOOTING [DWNEMA]
[DWNEMA] ABS CUT VALVE (R): MALFUNCTION (MA)

Trouble ABS cut valve (R): Malfunction (MA)
E03 DWNEMA ABS
Contents of trouble ABS cut valve (R) does not operate normally.
Related information

Defective ABS cut valve Replacing it with ABS cut valve pressure switch (F) restores the normal
1
pressure switch (R) state.
2 Defective ABS cut valve (R) Replacing ABS cut valve (R) restores the normal state.
Disconnection in wiring har- 2) Disconnect connectors ABS5A and CVSR.
Possible causes ness 3) Connect T-adapter.
in normal state Wiring harness between ABS5A (female) (3)
CVSR (female) (1)
2) Disconnect connectors ABS5A and CVSR.
4
ness
Wiring harness between ABS5A (female) (3) ,
CVSR (female) (1) chassis ground
20-1292 HD465-7, HD605-7

(12)
[DX21KA] ABS CONTROL VALVE FRONT WHEEL RIGHT (FR): DISCONNECTION (KA)

Trouble ABS control valve front wheel right (FR): Disconnection (KA)
E03 DX21KA ABS
Contents of trouble Current is not conducted as output is generated to ABS control valve (FR) circuit.
Related information

2) Disconnect connector ABS2 and ABSFR.
ness
ABSFR (female) (1)
contact)
Resistance Max. 1 z
Possible causes ABSFR (female) (2)
in normal state 2) Disconnect connector ABSFR.
Defective ABS control valve 3) Connect T-adapter.
2
(FR)
Across terminals between ABSFR (male) (1)
Resistance 10 30 z
ABSFR (male) (2)
Across terminals between ABS2 (female) (7)
Resistance 10 30 z
ABS2 (female) (17)
HD465-7, HD605-7 20-1293

(12)
[DX21KB] ABS CONTROL VALVE FRONT WHEEL RIGHT (FR): SHORT CIRCUIT (KB)

Trouble ABS control valve front wheel right (FR): Short circuit (KB)
E03 DX21KB ABS
Contents of trouble Excessive current is conducted as output is generated to ABS control valve (FR) circuit.
Related information

chassis ground
chassis ground
Possible causes 1) Turn off starting switch.
and standard value 2) Disconnect connector ABSFR.
Defective ABS control valve
2 Across terminals between ABSFR (male) (1)
(FR) Resistance 10 30 z
ABSFR (male) (2)
Wiring harness between ABSFR (male) (1)
chassis ground
Resistance 10 30 z
ABS2 (female) (17)
20-1294 HD465-7, HD605-7

(12)
[DX21KY] ABS CONTROL VALVE FRONT WHEEL RIGHT (FR): SHORT-CIRCUITED TO

POWER SUPPLY (KY)
Action code Failure code Controller code ABS control valve front wheel right (FR):
Trouble
E03 DX21KY ABS Short-circuited with power supply (KY)
Contents of trouble Current is conducted after output to ABS control valve (FR) circuit is turned off.
Related information

1 Hot short on wiring harness
and standard value Voltage Max. 1 V
ABSFR (female) (1) chassis ground
in normal state
Voltage Max. 1 V
ABSFR (female) (2) chassis ground
Resistance 10 30 z
ABS2 (female) (17)
HD465-7, HD605-7 20-1295

(12)
[DX21MA] ABS CONTROL VALVE FRONT WHEEL RIGHT (FR): MALFUNCTION (MA)

Trouble ABS control valve front wheel right (FR): Malfunction (MA)
E03 DX21MA ABS
Contents of trouble ABS cut valve (FR) does not operate normally.
Related information

Possible causes
Defective ABS control valve Replacing it with ABS control valve pressure sensor (FL) restores the
and standard value 1
pressure sensor (FR) normal state.
in normal state
2 Replacing it with ABS control valve (FL) restores the normal state.
(FR)
20-1296 HD465-7, HD605-7

(12)
[DX22KA] ABS CONTROL VALVE FRONT WHEEL LEFT (FL): DISCONNECTION (KA)

Trouble ABS control valve front wheel left (FL): Disconnection (KA)
E03 DX22KA ABS
Contents of trouble Current is not conducted as output is generated to ABS control valve (FL) circuit.
Related information

2) Disconnect connector ABS2 and ABSFL.
ness
ABSFL (female) (1)
contact)
Resistance Max. 1 z
Possible causes ABSFL (female) (2)
in normal state 2) Disconnect connector ABSFL.
2
(FL)
Across terminals between ABSFL (male) (1)
Resistance 10 30 z
ABSFL (male) (2)
Resistance 10 30 z
ABS2 (female) (18)
HD465-7, HD605-7 20-1297

(12)
[DX22KB] ABS CONTROL VALVE FRONT WHEEL LEFT (FL): SHORT CIRCUIT (KB)

Trouble ABS control valve front wheel left (FL): Short circuit (KB)
E03 DX22KB ABS
Contents of trouble Excessive current is conducted as output is generated to ABS control valve (FL) circuit.
Related information

chassis ground
chassis ground
and standard value 2) Disconnect connector ABSFL.
2 Across terminals between ABSFL (male) (1)
(FL) Resistance 10 30 z
ABSFL (male) (2)
Wiring harness between ABSFL (male) (1)
chassis ground
Resistance 10 30 z
ABS2 (female) (18)
20-1298 HD465-7, HD605-7

(12)
[DX22KY] ABS CONTROL VALVE FRONT WHEEL LEFT (FL): SHORT-CIRCUITED TO

POWER SUPPLY (KY)
Action code Failure code Controller code ABS control valve front wheel left (FL): Short-circuit to power
Trouble
E03 DX22KY ABS supply
Contents of trouble Current is conducted after output to ABS control valve (FL) circuit is turned off.
Related information

ABSFL (female) (1) chassis ground
in normal state
Voltage Max. 1 V
ABSFL (female) (2) chassis ground
Resistance 10 30 z
ABS2 (female) (18)
HD465-7, HD605-7 20-1299

(12)
[DX22MA] ABS CONTROL VALVE FRONT WHEEL LEFT (FL): MALFUNCTION (MA)

Trouble ABS control valve front wheel left (FL): Malfunction (MA)
E03 DX22MA ABS
Contents of trouble ABS cut valve (FL) does not operate normally.
Related information

Possible causes Defective ABS control valve Replacing it with ABS control valve pressure sensor (FR) restores the
and standard value 1 normal state.
pressure sensor (FL)
in normal state
2 Replacing it with ABS control valve (FR) restores the normal state.
(FL)
20-1300 HD465-7, HD605-7

(12)
[DX23KA] ABS CONTROL VALVE REAR WHEEL RIGHT (RR): DISCONNECTION (KA)

Trouble ABS control valve rear wheel right (RR): Disconnection (KA)
E03 DX23KA ABS
Contents of trouble Current is not conducted as output is generated to ABS control valve (RR) circuit.
Related information

2) Disconnect connector ABS2 and ABSRR.
ness
ABSRR (female) (1)
contact)
Resistance Max. 1 z
Possible causes ABSRR (female) (2)
in normal state 2) Disconnect connector ABSRR.
2
(RR)
Across terminals between ABSRR (male) (1)
Resistance 10 30 z
ABSRR (male) (2)
Resistance 10 30 z
ABS2 (female) (19)
HD465-7, HD605-7 20-1301

(12)
[DX23KB] ABS CONTROL VALVE REAR WHEEL RIGHT (RR): SHORT CIRCUIT (KB)

Trouble ABS control valve rear wheel right (RR): Short circuit (KB)
E03 DX23KB ABS
Contents of trouble Excessive current is conducted as output is generated to ABS control valve (RR) circuit.
Related information

chassis ground
chassis ground
and standard value 2) Disconnect connector ABSRR.
2 Across terminals between ABSRR (male) (1)
(FR) Resistance 10 30 z
ABSRR (male) (2)
Wiring harness between ABSRR (male) (1)
chassis ground
Resistance 10 30 z
ABS2 (female) (19)
20-1302 HD465-7, HD605-7

(12)
[DX23KY] ABS CONTROL VALVE REAR WHEEL RIGHT (RR): SHORT-CIRCUITED TO

POWER SUPPLY (KY)
Action code Failure code Controller code ABS control valve rear wheel right (RR):
Trouble
E03 DX23KY ABS Short-circuited to power supply (KY)
Contents of trouble Current is conducted after output to ABS control valve (RR) circuit is turned off.
Related information

ABSRR (female) (1) chassis ground
in normal state
Voltage Max. 1 V
ABSRR (female) (2) chassis ground
Resistance 10 30 z
ABS2 (female) (19)
HD465-7, HD605-7 20-1303

(12)
[DX23MA] ABS CONTROL VALVE REAR WHEEL RIGHT (RR): MALFUNCTION (MA)

Trouble ABS control valve rear wheel right (RR): Malfunction (MA)
E03 DX23MA ABS
Contents of trouble ABS control valve (RR) does not operate normally.
Related information

Possible causes Defective ABS control valve Replacing it with ABS control valve pressure sensor (RL) restores the
pressure sensor (RR)
in normal state
2 Replacing it with ABS control valve (RL) restores the normal state.
(RR)
20-1304 HD465-7, HD605-7

(12)
[DX24KA] ABS CONTROL VALVE REAR WHEEL LEFT (RL): DISCONNECTION (KA)

Trouble ABS control valve rear wheel left (RL): Disconnection (KA)
E03 DX24KA ABS
Contents of trouble Current is not conducted as output is generated to ABS control valve (RL) circuit.
Related information

2) Disconnect connector ABS2 and ABSRL.
ness
ABSRL (female) (1)
contact)
Resistance Max. 1 z
Possible causes ABSRL (female) (2)
in normal state 2) Disconnect connector ABSRL.
2
(RL)
Across terminals between ABSRL (male) (1)
Resistance 10 30 z
ABSRL (male) (2)
Resistance 10 30 z
ABS2 (female) (20)
HD465-7, HD605-7 20-1305

(12)
[DX24KB] ABS CONTROL VALVE REAR WHEEL LEFT (RL): SHORT CIRCUIT (KB)

Trouble ABS control valve rear wheel left (RL): Short circuit (KB)
E03 DX24KB ABS
Contents of trouble Excessive current is conducted as output is generated to ABS control valve (RL) circuit.
Related information

chassis ground
chassis ground
and standard value 2) Disconnect connector ABSRL.
2 Across terminals between ABSRL (male) (1)
(RL) Resistance 10 30 z
ABSRL (male) (2)
Wiring harness between ABSRL (male) (1)
chassis ground
Resistance 10 30 z
ABS2 (female) (20)
20-1306 HD465-7, HD605-7

(12)
[DX24KY] ABS CONTROL VALVE REAR WHEEL LEFT (RL): SHORT-CIRCUITED WITH
POWER SUPPLY (KY)
Action code Failure code Controller code ABS control valve rear wheel left (RL): Short-circuited with power
Trouble
E03 DX24KY ABS supply (KY)
Contents of trouble Current is conducted after output to ABS control valve (RL) circuit is turned off.
Related information

ABSRL (female) (1) chassis ground
in normal state
Voltage Max. 1 V
ABSRL (female) (2) chassis ground
Resistance 10 30 z
ABS2 (female) (20)
HD465-7, HD605-7 20-1307

(12)
[DX24MA] ABS CONTROL VALVE REAR WHEEL LEFT (RL): MALFUNCTION (MA)

Trouble ABS control valve rear wheel left (RL): Malfunction
E03 DX24MA ABS
Contents of trouble ABS control valve (RL) does not operate normally.
Related information

Possible causes Defective ABS control valve Replacing it with ABS control valve pressure sensor (RR) restores the
pressure sensor (RL)
in normal state
2 Replacing it with ABS control valve (FR) restores the normal state.
(RL)
20-1308 HD465-7, HD605-7

(12)
[DX25MA] ABS CONTROL VALVE (FRONT WHEEL SYSTEM): MALFUNCTION (MA)

Trouble ABS control valve (front wheel system): Malfunction (MA)
E03 DX25MA ABS
Contents of trouble ABS control valve (FR) or ABS control valve (FL) does not operate normally.
Related information

(FR)
Possible causes Turn on ABS system check and locate from the failure code (DX21MA
and standard value Defective ABS control valve
and DX22MA) which of front wheel right or left is responsible for mal-
in normal state (FL)
1 function of ABS control valve.
After confirmation, inspect and repair the valve according to the failure
pressure sensor (FR) code.
pressure sensor (FL)
HD465-7, HD605-7 20-1309

(12)
[DX26MA] ABS CONTROL VALVE (REAR WHEEL SYSTEM): MALFUNCTION (MA)

Trouble ABS control valve (rear wheel system): Malfunction (MA)
E03 DX26MA ABS
Contents of trouble ABS control valve (RR) or ABS control valve (RL) does not operate normally.
Related information

(RR)
Possible causes Turn on ABS system check and locate from the failure code (DX23MA
and standard value Defective ABS control valve
and DX24MA) which of front wheel right or left is responsible for mal-
in normal state (RL)
1 function of ABS control valve.
After confirmation, inspect and repair the valve according to the failure
pressure sensor (RR) code.
pressure sensor (RL)
20-1310 HD465-7, HD605-7

(12)

Códigos HD605-7

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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

No. X-type connector

Part No.: 08055-00282 Part No.: 08055-00292

Part No.: 08055-00381 Part No.: 08055-00391

Part No.: 08055-00481 Part No.: 08055-00491

20-318 HD465-7, HD605-7

No. SWP-type connector

Part No.: 08055-10881 Part No.: 08055- 10891

Part No.: 08055- 11281 Part No.: 08055- 11291

Part No.: 08055- 11481 Part No.: 08055-11491

HD465-7, HD605-7 20-319

No. SWP-type connector

Part No.: 08055-11681 Part No.: 08055-11691

20-320 HD465-7, HD605-7

No. M-type connector

Part No.: 08056-00271 Part No.: 08056-00281

Part No.: 08056-00371 Part No.: 08056-00381

Part No.: 08056-00471 Part No.: 08056-00481

Part No.: 08056-00671 Part No.: 08056-00681

Part No.: 08056-00871 Part No.: 08056-00881

HD465-7, HD605-7 20-321

Part No.: 08056-10871 Part No.: 08056-10881

Part No.: 08056-11071 Part No.: 08056-11081

Part No.: 08056-11271 Part No.: 08056-11281

Part No.: 08056-11671 Part No.: 08056-11681

20-322 HD465-7, HD605-7

Part No.: 08056-11272 Part No.: 08056-11282

Part No.: 08056-11672 Part No.: 08056-11682

HD465-7, HD605-7 20-323

MIC type connector

Housing part No.: 79A-222-2620 Housing part No.: 79A-222-2610

Housing part No.: 79A-222-2660 Housing part No.: 79A-222-2650

Housing part No.: 79A-222-2710 Housing part No.: 79A-222-2690

20-324 HD465-7, HD605-7

MIC type connector

Housing part No.: 79A-222-2730 Housing part No.: 79A-222-2720

Housing part No.: 79A-222-2750 Housing part No.: 79A-222-2740

HD465-7, HD605-7 20-325

Housing part No.: 79A-222-3430

Housing part No.: 79A-222-3440

Housing part No.: 79A-222-3450

Housing part No.: 79A-222-3460

20-326 HD465-7, HD605-7

Part No.: 7821-92-7330

Part No.: 7821-92-7340

Part No.: 7821-92-7350

Part No.: 7821-92-7360

Part No.: 7821-92-7370

HD465-7, HD605-7 20-327

20-328 HD465-7, HD605-7

KES 1 (Automobile) connector

Part No.: 08027-10310 Part No.: 08027-10360

HD465-7, HD605-7 20-329

KES 1 (Automobile) connector

20-330 HD465-7, HD605-7

Connector for relay (socket type)

HD465-7, HD605-7 20-331

20-332 HD465-7, HD605-7

Type HD30 series connector

Part No.: 08191-11201, 08191-11202, Part No.: 08191-14101, 08191-14102,

Part No.: 08191-12201, 08191-12202, Part No.: 08191-13101, 08191-13102,

Part No.: 08191-21201, 08191-12202, Part No.: 08191-24101, 08191-24102

Part No.: 08191-22201, 08191-22202, Part No.: 08191-23101, 08191-23102,