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Komatsu Dump Truck HD785-7 Shop Manual SEN01274-23 – PDF DOWNLOAD
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Komatsu Dump Truck HD785-7 Shop Manual
SERIAL NUMBERS 7001 and up
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Description
Komatsu Dump Truck HD785-7 Shop Manual
FILE DETAILS:
Komatsu Dump Truck HD785-7 Shop Manual
Brands: Komatsu
Equipment Type: Dump Truck
Manuals Type: Shop Manual
Machine Model: HD785-7
Serial Number: 7001 and up
Book Code: SEN01274-23
Language: English
Pages: 1892
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu Dump Truck HD785-7 Shop Manual
HOW TO READ THE SHOP MANUAL:
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. FOREWORD:
This section explains the safety and basic information.
01. GENERAL:
This section explains the specifications of the machine.
10. STRUCTURE AND FUNCTION, MAINTENANCE STANDARD:
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. TESTING AND ADJUSTING:
Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in
the Chassis volume and Engine volume. In this case, see the Chassis volume.
30. DISASSEMBLY AND ASSEMBLY:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. OTHERS (chassis volume)/Repair and replacement of parts (engine volume):
• Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
• Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
Komatsu Dump Truck HD785-7 Shop Manual
COVER .................................................................................................................................................................. 1 00 Index and foreword................................................................................................................................................... 0 Index............................................................................................................................................................... 3 Composition of shop manual...................................................................................................................................... 4 Table of contents............................................................................................................................................... 6 Foreword and general information.................................................................................................................................... 23 Safety notice................................................................................................................................................... 24 How to read the shop manual..................................................................................................................................... 29 Explanation of terms for maintenance standard................................................................................................................... 31 Handling of electric equipment and hydraulic component.......................................................................................................... 33 Handling of connectors newly used for engines................................................................................................................... 42 How to read electric wire code.................................................................................................................................. 45 Precautions when carrying out operation......................................................................................................................... 48 Method of disassembling and connecting push-pull type coupler................................................................................................... 51 Standard tightening torque table................................................................................................................................ 54 Conversion table................................................................................................................................................ 58 01 Specification........................................................................................................................................................ 0 Specification and technical data.................................................................................................................................... 65 Specification drawing........................................................................................................................................... 66 Specifications.................................................................................................................................................. 68 Weight table.................................................................................................................................................... 71 Fuel, coolant and lubricants.................................................................................................................................... 72 10 Structure, function and maintenance standard......................................................................................................................... 0 Engine and cooling system........................................................................................................................................... 77 Radiator, brake, torque converter oil cooler, aftercooler, steering, hoist oil cooler........................................................................... 78 Fuel system..................................................................................................................................................... 80 Power train, Part 1................................................................................................................................................. 83 Power train skeleton............................................................................................................................................ 84 Output shaft.................................................................................................................................................... 86 Drive shaft..................................................................................................................................................... 88 Torque converter and transmission hydraulic piping.............................................................................................................. 90 Brake cooling oil control valve (BCV)........................................................................................................................... 92 Torque converter................................................................................................................................................ 93 Torque converter valve.......................................................................................................................................... 101 Transmission.................................................................................................................................................... 104 Transmission control valve...................................................................................................................................... 132 ECMV............................................................................................................................................................ 134 Lubricating oil amount selector valve........................................................................................................................... 141 Power train, Part 2................................................................................................................................................. 145 Axle............................................................................................................................................................ 146 Differential.................................................................................................................................................... 148 Final drive..................................................................................................................................................... 149 Wheels.......................................................................................................................................................... 150 Steering system..................................................................................................................................................... 153 Steering column................................................................................................................................................. 154 Steering linkage................................................................................................................................................ 155 Brake system........................................................................................................................................................ 159 Brake piping.................................................................................................................................................... 160 Brake valve..................................................................................................................................................... 162 Secondary brake valve........................................................................................................................................... 165 Accumulator charge valve........................................................................................................................................ 166 Accumulator..................................................................................................................................................... 170 Slack adjuster.................................................................................................................................................. 172 Brake, parking brake............................................................................................................................................ 176 Parking brake solenoid.......................................................................................................................................... 182 Retarder control valve.......................................................................................................................................... 183 Exhaust brake................................................................................................................................................... 184 Undercarriage and frame............................................................................................................................................. 187 Suspension...................................................................................................................................................... 188 Suspension cylinder............................................................................................................................................. 190 Rear axle support............................................................................................................................................... 198 Hydraulic system.................................................................................................................................................... 201 Steering and hoist hydraulic piping............................................................................................................................. 202 Steering, hoist filter (high pressure circuit).................................................................................................................. 204 Dump body control............................................................................................................................................... 206 Power ladder system............................................................................................................................................. 208 Hydraulic tank.................................................................................................................................................. 215 Steering valve.................................................................................................................................................. 216 Crossover relief valve.......................................................................................................................................... 220 Steering cylinder............................................................................................................................................... 221 Steering control valve.......................................................................................................................................... 222 Hoist valve..................................................................................................................................................... 231 Dump control valve (EPC valve).................................................................................................................................. 237 Hydraulic pump.................................................................................................................................................. 240 Work equipment (Body)............................................................................................................................................... 245 Auto greasing system............................................................................................................................................ 246 Hoist cylinder.................................................................................................................................................. 257 Cab and its attachments............................................................................................................................................. 259 ROPS cab........................................................................................................................................................ 260 Air conditioner................................................................................................................................................. 261 Rear view monitor............................................................................................................................................... 270 Controller related.............................................................................................................................................. 273 Electrical system, Part 1........................................................................................................................................... 275 Machine monitor system.......................................................................................................................................... 276 Electrical system, Part 2........................................................................................................................................... 301 Automatic shift control system.................................................................................................................................. 302 External power supply heater.................................................................................................................................... 322 Automatic emergency steering system............................................................................................................................. 324 Automatic suspension system..................................................................................................................................... 328 Retarder control system......................................................................................................................................... 331 Battery disconnector switch..................................................................................................................................... 344 Emergency engine stop switch.................................................................................................................................... 348 Dump control lever.............................................................................................................................................. 350 Ladder control functio.......................................................................................................................................... 354 Electrical system, Part 3........................................................................................................................................... 357 VHMS controller related......................................................................................................................................... 358 ABS/ASR system.................................................................................................................................................. 384 Altitude setting function....................................................................................................................................... 402 Speed limit function............................................................................................................................................ 405 Electrical system, Part 4........................................................................................................................................... 411 Sensors, switches............................................................................................................................................... 412 20 Standard value table................................................................................................................................................. 0 Standard service value table........................................................................................................................................ 429 Standard value table for engine................................................................................................................................. 430 Standard value table for machine................................................................................................................................ 432 30 Testing and adjusting................................................................................................................................................ 0 Testing and adjusting, Part 1....................................................................................................................................... 445 Testing and adjusting tools list................................................................................................................................ 447 Sketch of special tool.......................................................................................................................................... 452 Testing engine speed............................................................................................................................................ 453 Testing air supply pressure (boost pressure).................................................................................................................... 454 Testing exhaust temperature..................................................................................................................................... 456 Testing exhaust gas color....................................................................................................................................... 458 Adjustment of valve clearance................................................................................................................................... 460 Testing compression pressure.................................................................................................................................... 462 Testing blow-by pressure........................................................................................................................................ 464 Testing engine oil pressure..................................................................................................................................... 465 Handling of fuel system devices................................................................................................................................. 466 Releasing residual pressure from fuel system.................................................................................................................... 466 Testing fuel pressure........................................................................................................................................... 467 Reduced cylinder mode operation................................................................................................................................. 468 No-injection cranking........................................................................................................................................... 468 Testing leakage-from pressure limiter and return rate from injector............................................................................................. 469 Bleeding air from fuel circuit (Standard spec.)................................................................................................................. 472 Bleeding air from fuel circuit (Extra low-grade fuel spec.)..................................................................................................... 474 Testing the fuel circuit for leakage............................................................................................................................ 476 Replacement and adjustment of fan belt.......................................................................................................................... 477 Testing and adjusting alternator belt tension................................................................................................................... 478 Testing and adjusting air conditioner compressor belt........................................................................................................... 479 Testing and adjusting, Part 2....................................................................................................................................... 481 Testing torque converter stall speed............................................................................................................................ 483 Testing power train oil pressure................................................................................................................................ 485 Adjusting transmission speed sensor............................................................................................................................. 493 Testing and adjusting brake oil pressure........................................................................................................................ 494 Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas........................................................... 497 Testing brake performance....................................................................................................................................... 502 Bleeding air from brake circuit................................................................................................................................. 504 Bleeding air from ASR circuit (if equipped)..................................................................................................................... 506 Testing wear of front brake disc................................................................................................................................ 507 Testing wear of rear brake disc................................................................................................................................. 508 Method of releasing parking brake in an emergency............................................................................................................... 509 Testing and adjusting front suspension cylinder................................................................................................................. 510 Testing and adjusting rear suspension cylinder.................................................................................................................. 514 Testing and adjusting front suspension cylinder (Automatic suspension specification)............................................................................ 518 Testing and adjusting hydraulic pressure in steering, hoist circuit............................................................................................. 519 Testing and adjusting oil pressure in dump EPC circuit.......................................................................................................... 522 Air bleeding from steering cylinder............................................................................................................................. 523 Procedure for raising dump body in emergency.................................................................................................................... 524 Adjusting body positioner sensor................................................................................................................................ 525 Handling of high voltage circuit of engine controller........................................................................................................... 527 Adjusting transmission controller............................................................................................................................... 527 Method for emergency escape at electrical system failure........................................................................................................ 528 Testing and adjusting ladder potentiometer...................................................................................................................... 532 Calibration method of ladder position........................................................................................................................... 533 Testing and adjusting, Part 3....................................................................................................................................... 537 Setting and adjusting of devices................................................................................................................................ 538 Testing and adjusting, Part 4....................................................................................................................................... 553 Special functions of machine monitor (EMMS)..................................................................................................................... 554 Testing and adjusting, Part 5....................................................................................................................................... 625 Opening ORBCOMM terminal........................................................................................................................................ 626 VHMS controller initial setting procedure....................................................................................................................... 628 Precautions for replacing VHMS controller....................................................................................................................... 653 Pm Clinic check sheet........................................................................................................................................... 659 Initial setting of payload meter................................................................................................................................ 663 Setting of payload meter built in VHMS.......................................................................................................................... 664 40 Troubleshooting...................................................................................................................................................... 0 Failure code table and fuse locations............................................................................................................................... 673 Failure codes table............................................................................................................................................. 674 Fuse locations.................................................................................................................................................. 690 General information on troubleshooting.............................................................................................................................. 697 Points to remember when troubleshooting......................................................................................................................... 698 Sequence of events in troubleshooting........................................................................................................................... 699 Check before troubleshooting.................................................................................................................................... 700 Classification and procedures for troubleshooting............................................................................................................... 701 Contents of troubleshooting table............................................................................................................................... 702 Connection table for connector pin numbers...................................................................................................................... 704 T- branch box and T- branch adapter table....................................................................................................................... 740 Troubleshooting by failure code, Part 1............................................................................................................................. 745 Failure code [1500L0] Dual engagement........................................................................................................................... 747 Failure code [15B0NX] Transmission oil filter: Clogging......................................................................................................... 748 Failure code [15F0KM] R → F shifting abuse 1: Mistake in operation.............................................................................................. 750 Failure code [15F0MB] R → F shifting abuse 2: Mistake in operation.............................................................................................. 750 Failure code [15F7KM] Forward clutch disk abuse: Mistake in operation or setting................................................................................ 751 Failure code [15G0MW] R clutch: Slipping........................................................................................................................ 752 Failure code [15G7KM] Reverse clutch disk abuse: Mistake in operation or setting................................................................................ 754 Failure code [15H0MW] Hi clutch: Slipping....................................................................................................................... 756 Failure code [15J0MW] Lo clutch: Slipping....................................................................................................................... 758 Failure code [15K0MW] 1st clutch: Slipping...................................................................................................................... 760 Failure code [15L0MW] 2nd clutch: Slipping...................................................................................................................... 762 Failure code [15M0MW] 3rd clutch: Slipping...................................................................................................................... 764 Failure code [15N0MW] 4th clutch: Slipping...................................................................................................................... 766 Failure code [15SBL1] R clutch solenoid: Fill signal is ON when command current is OFF.......................................................................... 768 Failure code [15SBMA] R clutch solenoid: Malfunction............................................................................................................ 770 Failure code [15SCL1] Hi clutch solenoid: Fill signal is ON when command current is OFF......................................................................... 772 Failure code [15SCMA] Hi clutch solenoid: Malfunction........................................................................................................... 775 Failure code [15SDL1] Lo clutch solenoid: Fill signal is ON when command current is OFF......................................................................... 776 Failure code [15SDMA] Lo clutch solenoid: Malfunction........................................................................................................... 779 Failure code [15SEL1] 1st clutch solenoid: Fill signal is ON when command current is OFF........................................................................ 780 Failure code [15SEMA] 1st clutch solenoid: Malfunction.......................................................................................................... 783 Troubleshooting by failure code, Part 2............................................................................................................................. 785 Failure code [15SFL1] 2nd clutch solenoid: Fill signal is ON when command current is OFF........................................................................ 788 Failure code [15SFMA] 2nd clutch solenoid: Malfunction.......................................................................................................... 791 Failure code [15SGL1] 3rd clutch solenoid: Fill signal is ON when command current is OFF........................................................................ 792 Failure code [15SGMA] 3rd clutch solenoid: Malfunction.......................................................................................................... 795 Failure code [15SHL1] 4th clutch solenoid: Fill signal is ON when command current is OFF........................................................................ 796 Failure code [15SHMA] 4th clutch solenoid: Malfunction.......................................................................................................... 799 Failure code [15SJMA] Lockup clutch solenoid: Malfunction....................................................................................................... 800 Failure code [2F00KM] Parking brake: Mistake in operation or setting............................................................................................ 802 Failure code [2G42ZG] Accumulator: Oil pressure reduction (Front)............................................................................................... 805 Failure code [2G43ZG] Accumulator: Oil pressure reduction (Rear)................................................................................................ 805 Failure code [989A00] Engine over run prevention command signal: Operating...................................................................................... 806 Failure code [989D00] Rear section tipping over alarm: Alarm is activated....................................................................................... 806 Failure code [989X00] Overspeed alarm: Alarm operation.......................................................................................................... 807 Failure code [989Y00] Overload alarm: Speed limit function operation............................................................................................ 807 Failure code [989Z00] Parking Brake Interlock Caution........................................................................................................... 808 Failure code [A570NX] Engine oil filter: Clogging............................................................................................................... 810 Failure code [AA10NX] Air cleaner element: Clogging............................................................................................................. 812 Failure code [AB00L4] Alternator: Failure on battery charge circuit (R terminal signal is present and engine is stopped)........................................ 814 Failure code [B@BAZK] Engine oil: Level too low................................................................................................................. 822 Failure code [B@BCNS] Engine: Overheat.......................................................................................................................... 824 Failure code [B@BCZK] Lowering of radiator coolant: Lowering of level........................................................................................... 826 Failure code [B@BFZK] Lowering of fuel level.................................................................................................................... 828 Failure code [B@C6NS] Brake cooling oil: Overheating (Front).................................................................................................... 829 Failure code [B@C7NS] Brake cooling oil: Overheating (Rear)..................................................................................................... 830 Failure code [B@CENS] Overheating of torque converter oil....................................................................................................... 832 Failure code [B@GAZK] Battery electrolyte level: Lowering of level.............................................................................................. 833 Failure code [B@JANS] Steering oil temperature: Overheat........................................................................................................ 834 Failure code [AB00MA] Alternator: Malfunction................................................................................................................... 816 Failure code [AB00MB] Alternator: Failure on battery charge circuit (Absence of R terminal signal and detection error).......................................... 818 Failure code [B@BAZG] Abnormal lowering of engine oil pressure: Lowering of oil pressure........................................................................ 820 Troubleshooting by failure code, Part 3............................................................................................................................. 837 Failure code [CA111] Engine controller (Left bank): Internal abnormality........................................................................................ 840 Failure code [CB111] Engine controller (Right bank): Internal abnormality....................................................................................... 842 Failure code [CA115] Abnormal engine Ne and Bkup speed sensors (Left bank): Abnormal speed sensor signal........................................................ 844 Failure code [CB115] Abnormal engine Ne and Bkup speed sensors (Right bank): Abnormal speed sensor signal....................................................... 845 Failure code [CA122] Charge pressure sensor too high (At left bank only): Excessively high voltage detected..................................................... 846 Failure code [CA123] Charge pressure sensor too low (At left bank only): Excessively low voltage detected....................................................... 848 Failure code [CA131] Throttle sensor high error (At left bank only)............................................................................................. 850 Failure code [CA132] Throttle sensor low error (At left bank only).............................................................................................. 853 Failure code [CA135] Oil pressure sensor too high (At left bank only): Excessively high voltage detected........................................................ 854 Failure code [CA141] Oil pressure sensor too low (At left bank only): Excessively low voltage detected.......................................................... 856 Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected..................................................................... 858 Failure code [CA145] Coolant temperature sensor too low (At left bank only): Excessively low voltage detected................................................... 860 Failure code [CA153] Charge temperature sensor too high (At left bank only): Excessively high voltage detected.................................................. 862 Failure code [CA154] Charge temperature sensor too low (At left bank only): Excessively low voltage detected.................................................... 864 Failure code [CA187] Sensor power supply (2) abnormally low level (Left bank): Low voltage detection............................................................ 866 Failure code [CB187] Sensor power supply (2) abnormally low level (Right bank): Low voltage detection........................................................... 866 Failure code [CA212] Engine oil temperature sensor abnormally high level (At left bank only): High voltage detection............................................ 868 Failure code [CA213] Engine oil temperature sensor abnormally low level (At left bank only): Low voltage detection.............................................. 870 Failure code [CA221] Atmospheric pressure sensor too high (At left bank only): Excessively high voltage detected................................................ 872 Failure code [CA222] Atmospheric pressure sensor too low (At left bank only): Excessively low voltage detected.................................................. 874 Failure code [CA227] Sensor power source (2) too high (Left bank): Excessively high voltage detected............................................................ 876 Failure code [CB227] Sensor power supply (2) abnormally high level (Right bank): High voltage detection......................................................... 878 Failure code [CA234] Engine over speed (At left bank only): Excessively high speed.............................................................................. 880 Failure code [CA238] Abnormal power source for Ne speed sensor (At left bank only): Excessively low voltage detected............................................ 882 Failure code [CB238] Abnormal power source for Ne speed sensor (At right bank only): Excessively low voltage detected........................................... 884 Failure code [CA263] Fuel temperature sensor too high (Left bank): Excessively high voltage detected............................................................ 886 Failure code [CB263] Fuel temperature sensor too high (Right bank): Excessively high voltage detected........................................................... 888 Failure code [CA265] Fuel temperature sensor abnormally low level (Left bank): Low voltage detection............................................................ 890 Failure code [CB265] Fuel temperature sensor abnormally low level (Right bank): Low voltage detection........................................................... 890 Failure code [CA271] PCV1 short circuit (Left bank): Short circuit.............................................................................................. 891 Failure code [CB271] PCV1 short circuit (Right bank): Short circuit............................................................................................. 892 Failure code [CA272] PCV1 disconnection (Left bank): Disconnection.............................................................................................. 893 Failure code [CB272] PCV1 disconnection (Right bank): Disconnection............................................................................................. 894 Failure code [CA273] PCV2 short circuit (Left bank): Short circuit.............................................................................................. 895 Failure code [CB273] PCV2 short circuit (Right bank): Short circuit............................................................................................. 896 Failure code [CA274] PCV2 disconnection (Left bank): Disconnection.............................................................................................. 897 Failure code [CB274] PCV2 disconnection (Right bank): Disconnection............................................................................................. 898 Troubleshooting by failure code, Part 4............................................................................................................................. 901 Failure code [CA322] Injector No. 1 (L/B No.1) system disconnection or short circuit (Left bank): Disconnection, short circuit.................................. 904 Failure code [CA323] Injector No. 5 (L/B No.5) system disconnection or short circuit (Left bank): Disconnection, short circuit.................................. 906 Failure code [CA324] Injector No. 3 (L/B No.3) system disconnection or short circuit (Left bank): Disconnection, short circuit.................................. 908 Failure code [CA325] Injector No. 6 (L/B No.6) system disconnection or short circuit (Left bank): Disconnection, short circuit.................................. 910 Failure code [CA331] Injector No. 2 (L/B No.2) system disconnection or short circuit (Left bank): Disconnection, short circuit.................................. 912 Failure code [CA332] Injector No. 4 (L/B No.4) system disconnection or short circuit (Left bank): Disconnection, short circuit.................................. 914 Failure code [CA342] Engine controller data mismatch (Left bank): Mismatch...................................................................................... 916 Failure code [CB342] Engine controller data mismatch (Right bank): Mismatch..................................................................................... 916 Failure code [CA351] Abnormal injector drive circuit (Left bank): Abnormal circuit.............................................................................. 918 Failure code [CB351] Injector drive circuit abnormality (Right bank): Circuit abnormality....................................................................... 920 Failure code [CA352] Sensor power supply (1) abnormally low level (Left bank): Low voltage detection............................................................ 922 Failure code [CB352] Sensor power supply (1) abnormally low level (Right bank): Low voltage detection........................................................... 922 Failure code [CA386] Sensor power supply (1) abnormally high level (Left bank): High voltage detection.......................................................... 924 Failure code [CB386] Sensor power supply (1) abnormally high level (Right bank): High voltage detection......................................................... 926 Failure code [CA431] Trouble in idle validation switch.......................................................................................................... 928 Failure code [CA432] Idle validation action error............................................................................................................... 932 Failure code [CA441] Power supply voltage abnormally low level (Left bank): Low voltage detection............................................................... 933 Failure code [CB441] Power supply voltage abnormally low level (Right bank): Low voltage detection.............................................................. 933 Failure code [CA442] Power supply voltage abnormally high level (Left bank): High voltage detection............................................................. 934 Failure code [CB442] Power supply voltage abnormally high level (Right bank): High voltage detection............................................................ 934 Failure code [CA449] Common rail abnormally high pressure (2) (Left bank): Abnormally high pressure occurrence.................................................. 935 Failure code [CB449] Common rail abnormally high pressure (2) (Right bank): Abnormally high pressure occurrence................................................. 935 Failure code [CA451] Common rail pressure sensor too high (Left bank): Excessively high voltage detected........................................................ 936 Failure code [CB451] Common rail pressure sensor abnormally high level (Right bank): High voltage detection..................................................... 938 Failure code [CA452] Common rail pressure sensor abnormally low level (Left bank): Abnormally low voltage detection............................................. 940 Failure code [CB452] Common rail pressure sensor abnormally low level (Right bank): Abnormally low voltage detection............................................ 940 Failure code [CA553] Common rail pressure too high (1) (Left bank): Excessively high pressure detected.......................................................... 941 Failure code [CB553] Common rail pressure too high (1) (Right bank): Excessively high pressure detected......................................................... 942 Failure code [CA554] In-range error in common rail pressure sensor (Left bank): In-range error.................................................................. 943 Failure code [CB554] In-range error in common rail pressure sensor (Right bank): In-range error................................................................. 943 Failure code [CA559] Loss of pressure feed from supply pump (1) (Left bank): Loss of pressure feed detected..................................................... 944 Failure code [CB559] Loss of pressure feed from supply pump (1) (Right bank): Loss of pressure feed detected.................................................... 948 Failure code [CA689] Abnormal engine Ne speed sensor (Left bank): Abnormal signal............................................................................... 952 Failure code [CB689] Abnormal engine Ne speed sensor (Right bank): Abnormal signal.............................................................................. 954 Failure code [CA691] Intake air temperature sensor abnormally high level (At left bank only): High voltage detection............................................ 956 Failure code [CA692] Intake air temperature sensor abnormally low level (At left bank only): Low voltage detection.............................................. 958 Failure code [CA731] Abnormal engine Bkup speed sensor phase (Left bank): Abnormal phase........................................................................ 959 Failure code [CB731] Abnormal engine Bkup speed sensor phase (Right bank): Abnormal phase....................................................................... 959 Troubleshooting by failure code, Part 5............................................................................................................................. 961 Failure code [CA757] Loss of all engine controller data (Left bank): Loss of all data........................................................................... 963 Failure code [CB757] Loss of all engine controller data (Right bank): Loss of all data.......................................................................... 963 Failure code [CA778] Abnormal engine Bkup speed sensor (Left bank): Abnormal Bkup signal........................................................................ 964 Failure code [CB778] Engine Bkup speed sensor abnormality (Right bank): Bkup signal error....................................................................... 966 Failure code [CA781] Inter-multicontroller communication error (Left bank): Communication error................................................................. 968 Failure code [CB781] Inter-multicontroller communication error (Right bank): Communication error................................................................ 970 Failure code [CA1257] Multicontroller distinction wiring harness key error (Left bank): Distinction error....................................................... 971 Failure code [CB1257] Multicontroller distinction wiring harness key error (Right bank): Distinction error...................................................... 972 Failure code [CB1548] Injector #7 (R/B #1) system disconnection/short circuit (Right bank): Disconnection/Short circuit......................................... 974 Failure code [CB1549] Injector #8 (R/B #2) system disconnection/short circuit (Right bank): Disconnection/Short circuit......................................... 976 Failure code [CB1551] Injector #10 (R/B #4) system disconnection/short circuit (Right bank): Disconnection/Short circuit........................................ 978 Failure code [CB1552] Injector #11 (R/B #5) system disconnection/short circuit (Right bank): Disconnection/Short circuit........................................ 980 Failure code [CB1553] Injector #12 (R/B #6) system disconnection/short circuit (Right bank): Disconnection/Short circuit........................................ 982 Failure code [CB1622] Injector #9 (R/B #3) system disconnection/short circuit (Right bank): Disconnection/Short circuit......................................... 984 Failure code [CA1633] KOMNET abnormality (Left bank): Communication error....................................................................................... 986 Failure code [CA2185] Throttle sensor supply voltage high error................................................................................................. 988 Failure code [CA2186] Throttle sensor power supply low error.................................................................................................... 990 Failure code [CA2249] Loss of pressure feed from supply pump (2) (Left bank): Loss of pressure feed detected.................................................... 991 Failure code [CB2249] Loss of pressure feed from supply pump (2) (Right bank): Loss of pressure feed detected................................................... 991 Failure code [CA2555] Intake heater relay voltage low error (Left bank)......................................................................................... 992 Failure code [CA2556] Intake heater relay voltage high error (Left bank)........................................................................................ 994 Troubleshooting by failure code, Part 6............................................................................................................................. 997 Failure code [D180KA] Preheating relay output system: Disconnection.............................................................................................1000 Failure code [D180KB] Preheating relay output system: Grounding fault...........................................................................................1001 Failure code [D180KY] Preheating relay output system: Hot short circuit.........................................................................................1002 Failure code [D19HKB] Stop lamp relay output system: Short circuit..............................................................................................1004 Failure code [D1EFKA] Pre-lubrication start relay output system: Disconnection..................................................................................1006 Failure code [D1EFKB] Pre-lubrication start relay output system: Grounding fault................................................................................1008 Failure code [D1EFKY] Pre-lubrication start relay output system: Hot short circuit..............................................................................1010 Failure code [D1EMKA] Disconnection of Parking Interlock Relay Output Circuit...................................................................................1012 Failure code [D1EMKB] Ground Fault of Parking Interlock Relay Output Circuit....................................................................................1013 Failure code [D1EMKY] Hot Short of Parking Interlock Relay Output Circuit.......................................................................................1014 Failure code [D1ENKZ] Failure of Power Ladder Power Supply Relay Output System..................................................................................1015 Failure code [D1EPKA] Disconnection of Power Ladder Pump Drive Relay Output Circuit.............................................................................1016 Failure code [D1EPKB] Ground Fault of Power Ladder Pump Drive Relay Output Circuit..............................................................................1017 Failure code [D1EPKY] Hot Short of Power Ladder Pump Drive Relay Output Circuit.................................................................................1018 Failure code [D1EQKA] Disconnection of Power Ladder Buzzer Relay Output Circuit.................................................................................1019 Failure code [D1EQKB] Ground Fault of Power Ladder Buzzer Relay Output Circuit..................................................................................1020 Failure code [D1EQKY] Hot Short of Power Ladder Buzzer Relay Output Circuit.....................................................................................1021 Failure code [D1ERKA] Open Circuit in Power Ladder Raise Solenoid Relay Output Circuit..........................................................................1022 Failure code [D1ERKB] Ground Fault of Power Ladder Raise Solenoid Relay Output Circuit..........................................................................1023 Failure code [D1ERKY] Hot Short in Power Ladder Raise Solenoid Relay Output Circuit.............................................................................1024 Failure code [D1ESKA] Open Circuit in Power Ladder Lower Solenoid Relay Output Circuit..........................................................................1025 Failure code [D1ESKB] Ground Fault of Power Ladder Lower Solenoid Relay Output Circuit..........................................................................1026 Failure code [D1ESKY] Hot Short in Power Ladder Lower Solenoid Relay Output Circuit.............................................................................1027 Failure code [DAF9KM] Wrong connection of connector.............................................................................................................1028 Failure code [DAFRKR] Abnormal CAN communication (machine monitor): Abnormal communication......................................................................1029 Failure code [DAQ0KK] Transmission controller direct power supply: Lowering of power supply voltage.............................................................1030 Failure code [DAQ0KT] Transmission controller nonvolatile memory: Abnormality in controller.....................................................................1032 Failure code [DAQ2KK] Transmission controller solenoid power supply: Power supply voltage too low...............................................................1034 Failure code [DAQ9KQ] Transmission controller: Disagreement of model selection..................................................................................1036 Failure code [DAQRKR] Abnormality in CAN communication (Transmission)...........................................................................................1037 Failure code [DAQRMA] Transmission controller option setting: Malfunction.......................................................................................1042 Failure code [DB10KT] Retarder controller nonvolatile memory: Abnormality in controller.........................................................................1042 Failure code [DB12KK] Retarder controller solenoid power supply: Power supply system trouble....................................................................1043 Failure code [DB13KK] Retarder controller battery direct power supply: Power supply voltage too low.............................................................1045 Failure code [DB19KQ] Disagreement of model selection (Retarder controller).....................................................................................1047 Failure code [DB1RKR] CAN communication (retarder controller): Communication disabled...........................................................................1048 Failure code [DB1RMA] Disagreement of option setting (Retarder controller)......................................................................................1052 Failure code [DB2RKR] CAN communication (engine controller): Communication disabled.............................................................................1053 Failure code [dB2RKR] CAN communication (engine controller): Communication disabled.............................................................................1059 Failure code [DBB0KK] or VHMS_LED display: "n9" → "01" VHMS controller: Low power supply voltage (input)........................................................1066 Failure code [DBB0KQ] (or VHMS_LED display: "nF" → "11") VHMS controller: Disagreement of model selection signals...............................................1068 Failure code [DBB3KK] (or VHMS_LED display: "n9" → "05") VHMS controller battery power supply: Low power supply voltage (input).................................1070 Failure code [DBB5KP] (or VHMS_LED display: "n9" → "04") VHMS controller 5 V power supply output: Low output voltage............................................1072 Failure code [DBB6KP] (or VHMS_LED display: "n9" → "02") VHMS controller 24 V power supply output: Low output voltage...........................................1074 Failure code [DBB7KP] (or VHMS_LED display: "n9" → "03") VHMS controller 12 V power supply output: Low output voltage...........................................1076 Failure code [DBBQKR] (or VHMS_LED display: "n8" → "02") VHMS controller CAN communication: Defective communication (Abnormality in target component system)....1077 Failure code [DBBRKR] Abnormality in CAN communication (VHMS)...................................................................................................1077 Failure code [DBC0KT] Abnormality of Non-volatile Memory........................................................................................................1078 Failure code [DBC2KK] ABS controller solenoid power supply: Power supply system trouble.........................................................................1080 Failure code [DBC2KK] Solenoid Power Supply: Low Voltage........................................................................................................1082 Failure code [DBC3KK] ABS controller battery direct power supply: Power supply voltage too low..................................................................1084 Failure code [DBC3KK] Direct Battery Power Supply: Low Voltage..................................................................................................1086 Failure code [DBC9KQ] Disagreement of model selection (ABS controller)..........................................................................................1088 Failure code [DBCRKR] Abnormality in CAN communication (ABS)....................................................................................................1089 Failure code [DBCRMA] Disagreement of option setting (ABS controller)...........................................................................................1093 Failure code [DBG2KK] Solenoid power supply: Low voltage........................................................................................................1094 Failure code [DBG3KK] Battery direct power supply: Low voltage..................................................................................................1096 Failure code [DBG9KQ] Model selection signal: Abnormal..........................................................................................................1098 Failure code [DDD7KX] Trouble in travel speed setting switch system: Out of input signal range..................................................................1100 Failure code [DDD8KA] ARSC system switch system: Disconnection (If equipped)....................................................................................1102 Failure code [DDD8KB] ARSC system switch system: Short circuit (If equipped)....................................................................................1104 Failure code [DDD9KA] ABS system switch system: Disconnection...................................................................................................1106 Failure code [DDD9KB] ABS system switch system: Short circuit...................................................................................................1108 Failure code [DDDAKA] ASR system switch: Disconnection..........................................................................................................1110 Failure code [DDDAKB] ASR system switch: Short circuit..........................................................................................................1112 Failure code [DDDGL4] Failure of ladder manual operation switch CH1 (inside cab) system.........................................................................1114 Failure code [DDDHL4] Failure of ladder manual operation switch CH2 (outside cab) system........................................................................1116 Failure code [DDE2KB] Engine oil pressure switch error: Grounding fault.........................................................................................1118 Failure code [DDE2L6] Engine oil pressure switch error: Disconnection or hot short circuit......................................................................1120 Failure code [DDP6L4] Service brake pressure switch trouble (Rear)..............................................................................................1122 Failure code [DDTHKA] Hi clutch fill switch: Disconnection......................................................................................................1124 Failure code [DDTJKA] Lo clutch fill switch: Disconnection......................................................................................................1126 Failure code [DDTKKA] 1st clutch fill switch: Disconnection.....................................................................................................1128 Failure code [DDTLKA] 2nd clutch fill switch: Disconnection.....................................................................................................1130 Failure code [DDTMKA] 3rd clutch fill switch: Disconnection.....................................................................................................1132 Failure code [DDTNKA] R clutch fill switch: Disconnection.......................................................................................................1134 Failure code [DDTPKA] 4th clutch fill switch: Disconnection.....................................................................................................1136 Failure code [DDU1KA] Open Circuit in Parking Brake Operation Input Circuit.....................................................................................1138 Failure code [DF10KA] Gear shift lever: Disconnection...........................................................................................................1139 Failure code [DF10KB] Gear shift lever: Short circuit...........................................................................................................1142 Failure code [DGE5KX] or VHMS_LED display: "n4" → "01"..........................................................................................................1146 Failure code [DGF1KX] Transmission oil temperature sensor: Out of input signal range............................................................................1148 Failure code [DGR2KB] Trouble in retarder oil temperature sensor (rear wheel) system (Disconnection and short circuit)..........................................1150 Failure code [DGR2KZ] Trouble in retarder oil temperature sensor (rear wheel) system (Ground fault).............................................................1152 Failure code [DGR4KB] Trouble in retarder oil temperature sensor (front wheel) system (Disconnection and short circuit).........................................1153 Failure code [DGR4KZ] Trouble in retarder oil temperature sensor (front wheel) system (Ground fault)............................................................1154 Failure code [DGR6KX] Steering oil temperature sensor: Input signal out of range................................................................................1156 Failure code [DGT1KX] Torque converter oil temperature sensor: Out of input signal range........................................................................1158 Troubleshooting by failure code, Part 7.............................................................................................................................1161 Failure code [DGT5KA] (or VHMS_LED display: "n3" → "12") Left bank exhaust temperature sensor system (Front): Disconnection.....................................1163 Failure code [dGT5KA] (or VHMS_LED display: "n3" → "22") Left bank exhaust temperature sensor system (Rear): Disconnection......................................1166 Failure code [DGT5KB] (or VHMS_LED display: "n3" → "11") Left bank exhaust temperature sensor system (Front): Short circuit.....................................1169 Failure code [dGT5KB] (or VHMS_LED display: "n3" → "21") Left bank exhaust temperature sensor system (Rear): Short circuit......................................1172 Failure code [DGT6KA] (or VHMS_LED display: "n3" → "24") Right bank exhaust temperature sensor system (Front): Disconnection....................................1175 Failure code [dGT6KA] (or VHMS_LED display: "n3" → "26") Right bank exhaust temperature sensor system (Rear): Disconnection.....................................1178 Failure code [DGT6KB] (or VHMS_LED display: "n3" → "23") Right bank exhaust temperature sensor system (Front): Short circuit....................................1181 Failure code [dGT6KB] (or VHMS_LED display: "n3" → "25") Right bank exhaust temperature sensor system (Rear): Short circuit.....................................1184 Failure code [DHE5KB] or VHMS_LED display: "n3" → "32" Blow-bypressure sensor: Short circuit...................................................................1187 Failure code [DHE5KY] (or VHMS_LED display: "n3" → "31") (Blow-by pressure sensor: Short circuit with power supply line)........................................1190 Failure code [DHP4KY] (or VHMS_LED display: "n5" → "44") Suspension pressure sensor system: Short circuit (Right front).........................................1192 Failure code [DHP4KZ] (or VHMS_LED display: "n5" → "43") Suspension pressure sensor system: Disconnection or ground fault (Right front).........................1194 Failure code [DHP5KY] (or VHMS_LED display: "n5" → "54") Suspension pressure sensor system: Short circuit (Left front)..........................................1196 Failure code [DHP5KZ] (or VHMS_LED display: "n5" → "53") Suspension pressure sensor system: Disconnection or ground fault (Left front)..........................1198 Failure code [DHP6KA] Suspension pressure sensor system: Disconnection (Right rear).............................................................................1200 Failure code [DHP6KX] Failure in suspension pressure sensor system trouble: Out of input signal range (Right rear)..............................................1201 Failure code [DHP6KY] (or VHMS_LED display: "n5" → "64") Suspension pressure sensor system: Short circuit (Right rear)..........................................1204 Failure code [DHP6KZ] (or VHMS_LED display: "n5" → "63") Suspension pressure sensor system: Disconnection or ground fault (Right rear)..........................1206 Failure code [DHP7KA] Suspension pressure sensor system: Disconnection (Left rear)..............................................................................1208 Failure code [DHP7KX] Failure in suspension pressure sensor system trouble: Out of input signal range (Left rear)...............................................1209 Failure code [DHP7KY] (or VHMS_LED display: "n5" → "74") Suspension pressure sensor system: Short circuit (Left rear)...........................................1212 Failure code [DHP7KZ] (or VHMS_LED display: "n5" → "73") Suspension pressure sensor system: Disconnection or ground fault (Left rear)...........................1214 Failure code [DHT5KX] Torque converter oil pressure sensor: Out of input signal range...........................................................................1216 Failure code [DHT5L6] Torque converter oil pressure sensor: Disagreement of run and stop condition with signal..................................................1218 Failure code [DHU2KX] Front accumulator oil pressure sensor: Out of input signal range..........................................................................1220 Failure code [DHU3KX] Rear accumulator oil pressure sensor: Out of input signal range...........................................................................1222 Failure code [DHU6KX] Trouble in ABS control valve pressure sensor (Front right)................................................................................1224 Failure code [DHU7KX] Trouble in ABS control valve pressure sensor (Front left).................................................................................1226 Failure code [DHU8KX] Trouble in ABS control valve pressure sensor (Rear right).................................................................................1228 Failure code [DHU9KX] Trouble in ABS control valve pressure sensor (Rear left)..................................................................................1230 Failure code [DJF1KA] Fuel level sensor: Disconnection..........................................................................................................1232 Failure code [DK30KX] Steering angle potentiometer: Trouble (Disconnection).....................................................................................1234 Failure code [DK51L5] Retarder lever potentiometer: Potentiometer signal is inconsistent with swich signal......................................................1235 Failure code [DK52KX] Failure in hoist lever potentiometer 1: Out of input signal range.........................................................................1238 Failure code [DK53L8] Failure in hoist lever potentiometer 2: Disagreement of analog signal.....................................................................1240 Failure code [DK54KX] Body positioner sensor: Out of input signal range.........................................................................................1242 Failure code [DK5VKX] Abnormality of Power Ladder Position Input Signal(Out of Range)...........................................................................1244 Failure code [DK5VMA] Power Ladder System Abnormality...........................................................................................................1246 Failure code [DKD0L6] Failure in steering speed sensor..........................................................................................................1248 Failure code [DKH0KX] Clinometer sensor signal out of range.....................................................................................................1250 Failure code [DKH1KX] (or VHMS_LED display: "n4"→"33") Abnormality in clinometer sensor.........................................................................1252 Failure code [DLF1KA] Transmission input shaft speed sensor: Disconnection......................................................................................1254 Failure code [DLF1LC] Transmission input shaft speed sensor: Disagreement of revolution speed signal............................................................1256 Failure code [DLF2KA] Transmission intermediate shaft speed sensor: Disconnection...............................................................................1258 Failure code [DLF2LC] Transmission intermediate shaft speed sensor: Disagreement of revolution speed signal.....................................................1260 Troubleshooting by failure code, Part 8.............................................................................................................................1263 Failure code [DLF6KA] Disconnection in wheel speed sensor (Front right).........................................................................................1266 Failure code [DLF6L3] Trouble in wheel speed sensor (Front right)...............................................................................................1268 Failure code [DLF7KA] Disconnection in wheel speed sensor (Front left)..........................................................................................1270 Failure code [DLF7L3] Trouble in wheel speed sensor (Front left)................................................................................................1272 Failure code [DLF8KA] Wheel speed sensor: Disconnection (Rear right)............................................................................................1274 Failure code [DLF8L3] Wheel speed sensor: Disconnection (Rear right)............................................................................................1276 Failure code [DLF8LC] Wheel speed sensor: Trouble (Rear right)..................................................................................................1278 Failure code [DLF8MA] Wheel speed sensor: Disconnection (Rear right)............................................................................................1278 Failure code [DLF9KA] Wheel speed sensor: Disconnection (Rear left).............................................................................................1280 Failure code [DLF9L3] Wheel speed sensor: Trouble (Rear left)...................................................................................................1282 Failure code [DLF9LC] Wheel speed sensor: Trouble (Rear left)...................................................................................................1284 Failure code [DLF9MA] Wheel speed sensor: Disconnection (Rear left).............................................................................................1284 Failure code [DLT3KA] Transmission output shaft speed sensor: Disconnection.....................................................................................1286 Failure code [DLT3LC] Transmission output shaft speed sensor: Disagreement of revolution speed signal...........................................................1288 Failure code [DLT4KA] Transmission output shaft speed sensor: Disconnection.....................................................................................1290 Failure code [DLT4MA] Transmission output shaft speed sensor: Disconnection.....................................................................................1292 Failure code [DUM7KY] Pre-lubrication operation lamp output abnormality: Hot short circuit......................................................................1294 Failure code [DUM7KZ] Pre-lubrication operation lamp output abnormality: Disconnection or grounding fault.......................................................1296 Failure code [DUM9KZ] Failure of power ladder indicator system..................................................................................................1298 Failure code [DV00KB] Buzzer output: Short circuit..............................................................................................................1300 Failure code [DW2AKA] Main pressure variable valve output: Disconnection........................................................................................1302 Failure code [DW2AKB] Main pressure variable valve output circuit: Ground fault.................................................................................1304 Failure code [DW2AKY] Main pressure variable valve output circuit: Hot short....................................................................................1306 Failure code [DW2AL1] Main pressure variable valve: Defective reset.............................................................................................1308 Failure code [DW2ALH] Main pressure variable valve: Malfunction.................................................................................................1310 Failure code [DW2BKA] Main oil level selector valve output: Disconnection.......................................................................................1311 Failure code [DW2BKB] Main oil level selector valve output circuit: Ground fault................................................................................1312 Failure code [DW2BKY] Main oil level selector valve output circuit: Hot short...................................................................................1314 Failure code [DW2BL1] Main oil level selector valve: Defective reset............................................................................................1316 Failure code [DW2BLH] Main oil level selector valve: Malfunction................................................................................................1318 Failure code [DW2CKA] Transmission lubrication variable valve output: Disconnection.............................................................................1319 Failure code [DW2CKB] Transmission lubrication variable valve outputcircuit: Ground fault......................................................................1320 Failure code [DW2CKY] Transmission lubrication variable valve output circuit: Hot short.........................................................................1322 Failure code [DW2CL1] Transmission lubrication variable valve: Defective reset..................................................................................1324 Failure code [DW2CLH] Transmission lubrication variable valve: Malfunction......................................................................................1326 Failure code [DW35KZ] Failure in output system of auto suspension solenoid 1: Disconnection or short circuit....................................................1328 Failure code [DW36KZ] Failure in output system of auto suspension solenoid 2: Disconnection or short circuit....................................................1330 Failure code [DW71KZ] Exhaust brake output system trouble (Disconection/Ground fault/Hot short).................................................................1332 Failure code [DW72KZ] Kick-out solenoid output system trouble: Disconnection or short circuit...................................................................1334 Failure code [DW73KZ] Failure in hoist select valve output system: Disconnection or short circuit...............................................................1336 Failure code [DW78KZ] Brake cooling valve (BCV) (rear wheel) output system trouble: Disconnection or short circuit..............................................1338 Failure code [DWNBK4] ASR shut-off valve: Trouble (Valve keeps operating).......................................................................................1340 Failure code [DWNBKA] ASR shut-off valve output circuit: Disconnection..........................................................................................1342 Failure code [DWNBKB] ASR shut-off valve output circuit: Ground fault...........................................................................................1344 Failure code [DWNBKY] ASR shut-off valve output circuit: Short circuit..........................................................................................1346 Failure code [DWNBMA] ASR shut-off valve: Trouble (Valve does not operate)......................................................................................1347 Failure code [DWNDKZ] Trouble in ABS cut-off valve (Front) system...............................................................................................1348 Failure code [DWNDMA] Defective ABS cut-off valve (Front).......................................................................................................1350 Failure code [DWNEKZ] Trouble in ABS cut-off valve (Rear) system................................................................................................1352 Failure code [DWNEMA] Defective ABS cut-off valve (Rear)........................................................................................................1354 Failure code [DWNLKA] Open Circuit in Power Ladder Shock Reducing Solenoid Output Circuit.......................................................................1356 Failure code [DWNLKB] Ground Fault of Power Ladder Shock Reducing Solenoid Output Circuit.......................................................................1357 Failure code [DWNLKY] Hot Short in Power Ladder Shock Reducing Solenoid Output Circuit..........................................................................1358 Troubleshooting by failure code, Part 9.............................................................................................................................1361 Failure code [DX11K4] Rear brake proportional pressure reducing solenoid valve: Out of control..................................................................1364 Failure code [DX11KA] Rear brake proportional pressure reducing solenoid valve output circuit: Disconnection....................................................1366 Failure code [DX11KB] Rear brake proportional pressure reducing solenoid valve: Short circuit...................................................................1367 Failure code [DX11KY] Rear brake proportional pressure reducing solenoid valve: Short circuit to power source line..............................................1368 Failure code [DX11MA] Rear brake proportional pressure reducing solenoid valve: Malfunction.....................................................................1370 Failure code [DX12K4] Front brake proportional pressure reducing solenoid valve: Out of control.................................................................1372 Failure code [DX12KA] Front brake proportional pressure reducing solenoid valve output circuit: Disconnection...................................................1374 Failure code [DX12KB] Front brake proportional pressure reducing solenoid valve: Short circuit..................................................................1375 Failure code [DX12KY] Front brake proportional pressure reducing solenoid valve: Short circuit to power source line.............................................1376 Failure code [DX12MA] Front brake proportional pressure reducing solenoid valve: Malfunction....................................................................1378 Failure code [DX13KA] Output circuit of hoist EPC valve: Disconnection..........................................................................................1380 Failure code [DX13KB] Output circuit of hoist EPC valve: Short circuit..........................................................................................1382 Failure code [DX13KY] Output circuit of hoist EPC valve: Short circuit with power source line...................................................................1384 Failure code [DX17K4] ASR proportional pressure reducing solenoid valve (right): Trouble (Valve keeps operating)................................................1386 Failure code [DX17KA] ASR proportional pressure reducing solenoid valve (right) output circuit: Disconnection...................................................1388 Failure code [DX17KB] ASR proportional pressure reducing solenoid valve (right) output circuit: Ground fault....................................................1390 Failure code [DX17KY] ASR proportional pressure reducing solenoid valve (right) output circuit: Short circuit...................................................1392 Failure code [DX17MA] ASR proportional pressure reducing solenoid valve (right): Trouble (Valve does not operate)...............................................1392 Failure code [DX18K4] ASR proportional pressure reducing solenoid valve (left): Trouble (Valve keeps operating).................................................1394 Failure code [DX18KA] ASR proportional pressure reducing solenoid valve (left) output circuit: Disconnection....................................................1396 Failure code [DX18KB] ASR proportional pressure reducing solenoid valve (left) output circuit: Ground fault.....................................................1398 Failure code [DX18KY] ASR proportional pressure reducing solenoid valve (left) output circuit: Short circuit....................................................1400 Failure code [DX18MA] ASR proportional pressure reducing solenoid valve (left): Trouble (Valve does not operate)................................................1400 Failure code [DX21KA] Disconnection in ABS control valve output circuit (Front right)...........................................................................1401 Failure code [DX21KB] Ground fault in ABS control valve output circuit (Front right)............................................................................1402 Failure code [DX21KY] Hot short in ABS control valve output circuit (Front right)...............................................................................1403 Failure code [DX21MA] Defective ABS control valve (Front right).................................................................................................1404 Failure code [DX22KA] Disconnection in ABS control valve output circuit (Front left)............................................................................1405 Failure code [DX22KB] Ground fault in ABS control valve output circuit (Front left).............................................................................1406 Failure code [DX22KY] Hot short in ABS control valve output circuit (Front left)................................................................................1407 Failure code [DX22MA] Defective ABS control valve (Front left)..................................................................................................1408 Failure code [DX23KA] Disconnection in ABS control valve output circuit (Rear right)............................................................................1409 Failure code [DX23KB] Ground fault in ABS control valve output circuit (Rear right).............................................................................1410 Failure code [DX23KY] Hot short in ABS control valve output circuit (Rear right)................................................................................1411 Failure code [DX23MA] Defective ABS control valve (Rear right)..................................................................................................1412 Failure code [DX24KA] Disconnection in ABS control valve output circuit (Rear left).............................................................................1413 Failure code [DX24KB] Ground fault in ABS control valve output circuit (Rear left)..............................................................................1414 Failure code [DX24KY] Hot short in ABS control valve output circuit (Rear left).................................................................................1415 Failure code [DX24MA] Defective ABS control valve (Rear left)...................................................................................................1416 Failure code [DX25MA] Defective ABS front wheel system control valve............................................................................................1417 Failure code [DX26MA] Defective ABS rear wheel system control valve.............................................................................................1417 Troubleshooting by failure code, Part 10............................................................................................................................1419 Failure code [DXH1KA] Lockup clutch solenoid output circuit: Disconnection......................................................................................1422 Failure code [DXH1KB] Lockup clutch solenoid output circuit: Short circuit......................................................................................1424 Failure code [DXH1KY] Lockup clutch solenoid output circuit: Short circuit to power supply line.................................................................1426 Failure code [DXH2KA] Hi clutch solenoid output circuit: Disconnection..........................................................................................1428 Failure code [DXH2KB] Hi clutch solenoid output circuit: Short circuit..........................................................................................1430 Failure code [DXH2KY] Hi clutch solenoid output circuit: Short circuit to power supply line.....................................................................1432 Failure code [DXH3KA] Lo clutch solenoid output circuit: Disconnection..........................................................................................1436 Failure code [DXH3KB] Lo clutch solenoid output circuit: Short circuit..........................................................................................1438 Failure code [DXH3KY] Lo clutch solenoid output circuit: Short circuit in power supply line.....................................................................1440 Failure code [DXH4KA] 1st clutch solenoid output circuit: Disconnection.........................................................................................1444 Failure code [DXH4KB] 1st clutch solenoid output circuit: Short circuit.........................................................................................1446 Failure code [DXH4KY] 1st clutch solenoid output circuit: Short circuit to power supply line....................................................................1448 Failure code [DXH5KA] 2nd clutch solenoid output circuit: Disconnection.........................................................................................1452 Failure code [DXH5KB] 2nd clutch solenoid output circuit: Short circuit.........................................................................................1454 Failure code [DXH5KY] 2nd clutch solenoid output circuit: Short circuit in power supply line....................................................................1456 Failure code [DXH6KA] 3rd clutch solenoid output circuit: Disconnection.........................................................................................1460 Failure code [DXH6KB] 3rd clutch solenoid output circuit: Short circuit.........................................................................................1462 Failure code [DXH6KY] 3rd clutch solenoid output circuit: Short circuit to power supply line....................................................................1464 Failure code [DXH7KA] R clutch solenoid output circuit: Disconnection...........................................................................................1468 Failure code [DXH7KB] R clutch solenoid output circuit: Short circuit...........................................................................................1470 Failure code [DXH7KY] R clutch solenoid output circuit: Short circuit to power supply line......................................................................1472 Failure code [DXHHKA] 4th clutch solenoid output circuit: Disconnection.........................................................................................1474 Failure code [DXHHKB] 4th clutch solenoid output circuit: Short circuit.........................................................................................1476 Failure code [DXHHKY] 4th clutch solenoid output circuit: Short circuit to power supply line....................................................................1478 Failure code [F@BBZL] or VHMS_LED display: "n3"o"38" Blow-by pressure: High error...............................................................................1481 Failure code [F@BYNS] (or VHMS_LED display "n3" → "61") Left front exhaust temperature sensor (1): Exhaust temperature abnormal rise............................1482 Failure code [f@BYNS] (or VHMS_LED display "n3" → "71") Left rear exhaust temperature sensor (1): Exhaust temperature abnormal rise.............................1484 Failure code [F@BZNS] (or VHMS_LED display "n3" → "81") Right front exhaust temperature sensor (1): Exhaust temperature abnormal rise...........................1486 Failure code [f@BZNS] (or VHMS_LED display "n3" → "91") Right rear exhaust temperature sensor (1): Exhaust temperature abnormal rise............................1488 Failure code [F@BYNR] (or VHMS_LED display "n3" → "62") Left front exhaust temperature sensor (2): Exhaust temperature abnormal rise............................1490 Failure code [f@BYNR] (or VHMS_LED display "n3" → "72") Left rear exhaust temperature sensor (2): Exhaust temperature abnormal rise.............................1492 Failure code [F@BZNR] (or VHMS_LED display "n3" → "82") Right front exhaust temperature sensor (2): Exhaust temperature abnormal rise...........................1494 Failure code [f@BZNR] (or VHMS_LED display "n3" → "92") Right rear exhaust temperature sensor (2): Exhaust temperature abnormal rise............................1496 Troubleshooting of electrical system (E-mode).......................................................................................................................1499 Before troubleshooting of electric system.......................................................................................................................1501 Contents of troubleshooting table...............................................................................................................................1502 E-1 Engine does not start.......................................................................................................................................1503 E-2 Automatic preheating does not operate.......................................................................................................................1506 E-3 Machine monitor does not display all, when starting switch is turned ON.....................................................................................1510 E-4 Machine monitor does not operate when starting switch is OFF................................................................................................1512 E-5 Alarm buzzer does not sound.................................................................................................................................1514 E-6 Alarm buzzer does not stop sounding.........................................................................................................................1516 E-7 Gauges of machine monitor, caution lamps or character display section do not display properly...............................................................1517 E-8 A selection of the display in character display section cannot be changed...................................................................................1519 E-9 Power mode selecting function does not operate properly.....................................................................................................1522 E-10 AISS function does not operate properly....................................................................................................................1523 E-11 Seat belt caution lamp does not display properly...........................................................................................................1524 E-12 Turn signal lamp or turning lamp (hazard lamp) do not work properly........................................................................................1525 E-13 Night illumination (lighting) does not work properly.......................................................................................................1528 E-14 Emergency steering does not operate........................................................................................................................1540 E-15 Hoist lever does not operate normally......................................................................................................................1546 E-16 Power supply system (Air conditioner does not operate).....................................................................................................1548 E-17 Compressor and refrigerant system (Air is not cooled)......................................................................................................1550 E-18 Blower motor system (Air does not come out or air flow is abnormal)........................................................................................1552 E-19 Ladder cannot be lowered with operation switch outside cab.................................................................................................1554 E-20 Ladder cannot be lowered with operation switch inside cab..................................................................................................1555 E-21 Ladder continues lowering..................................................................................................................................1556 E-22 Ladder cannot be raised with operation switch outside cab..................................................................................................1557 E-23 Ladder cannot be lowered with operation switch inside cab..................................................................................................1558 E-24 Ladder continues rising....................................................................................................................................1559 E-25 Buzzer does not sound when power ladder is operated........................................................................................................1560 E-26 Power ladder pump does not operate.........................................................................................................................1561 Troubleshooting of hydraulic and mechanical system (H-mode).........................................................................................................1563 Contents of troubleshooting table...............................................................................................................................1565 H-1 Machine does not start......................................................................................................................................1566 H-2 Machine does not travel smoothly (hunting)..................................................................................................................1568 H-3 Lockup cannot be cancelled..................................................................................................................................1568 H-4 Excessive shock when starting or shifting excessive.........................................................................................................1569 H-5 Transmission does not shift up..............................................................................................................................1570 H-6 Machine lacks power or speed when traveling.................................................................................................................1572 H-7 Time lag is excessive when starting or shifting gear........................................................................................................1576 H-8 Torque converter oil temperature is high....................................................................................................................1578 H-9 Torque converter oil pressure is low........................................................................................................................1579 H-10 Front brake is ineffective.................................................................................................................................1580 H-11 Rear brake is ineffective..................................................................................................................................1581 H-12 Steering wheel is heavy....................................................................................................................................1582 H-13 Steering wheel does not work...............................................................................................................................1583 H-14 Steering wheel vibrates....................................................................................................................................1584 H-15 Dump body lifting speed is slow............................................................................................................................1585 H-16 Dump body does not work....................................................................................................................................1586 H-17 Excessive hydraulic drift of dump body.....................................................................................................................1587 H-18 Power ladder does not move or its speed is low.............................................................................................................1588 Troubleshooting of engine (S-mode)..................................................................................................................................1589 Method of using troubleshooting charts..........................................................................................................................1591 S-1 Starting performance is poor................................................................................................................................1594 S-2 Engine does not start.......................................................................................................................................1595 S-3 Engine does not pick up smoothly............................................................................................................................1598 S-4 Engine stops during operations..............................................................................................................................1599 S-5 Engine does not rotate smoothly.............................................................................................................................1600 S-6 Engine lacks output (or lacks power)........................................................................................................................1601 S-7 Exhaust smoke is black (incomplete combustion)..............................................................................................................1603 S-8 Oil consumption is excessive (or exhaust smoke is blue).....................................................................................................1604 S-9 Oil becomes contaminated quickly............................................................................................................................1605 S-10 Fuel consumption is excessive..............................................................................................................................1606 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)......................................................................................1607 S-12 Oil pressure drops.........................................................................................................................................1608 S-13 Oil level rises (Entry of coolant or fuel).................................................................................................................1609 S-14 Coolant temperature becomes too high (overheating).........................................................................................................1610 S-15 Abnormal noise is made.....................................................................................................................................1611 S-16 Vibration is excessive.....................................................................................................................................1612 50 Disassembly and assembly............................................................................................................................................. 0 General information on disassembly and assembly.....................................................................................................................1615 How to read this manual.........................................................................................................................................1616 Coating materials list..........................................................................................................................................1618 Special tool list...............................................................................................................................................1621 Sketches of special tools.......................................................................................................................................1624 Engine and cooling system...........................................................................................................................................1631 Removal and installation of fuel supply pump assembly...........................................................................................................1632 Removal and installation of fuel injector assembly..............................................................................................................1634 Removal and installation of cylinder head assembly..............................................................................................................1635 Removal and installation of engine hood assembly................................................................................................................1648 Removal and installation of radiator assembly...................................................................................................................1649 Removal and installation of engine assembly.....................................................................................................................1658 Removal and installation of engine front oil seal...............................................................................................................1663 Removal and installation of engine rear oil seal................................................................................................................1666 Power train, Part 1.................................................................................................................................................1671 Removal and installation of front drive shaft...................................................................................................................1672 Removal and installation of rear drive shaft....................................................................................................................1674 Removal and installation of output shaft assembly...............................................................................................................1675 Disassembly and assembly of damper assembly.....................................................................................................................1680 Removal and installation of torque converter and transmission assembly..........................................................................................1682 Disconnection and connection of torque converter assembly and transmission assembly.............................................................................1685 Disassembly and assembly of torque converter PTO assembly.......................................................................................................1692 Disassembly and assembly of transmission assembly...............................................................................................................1705 Power train, Part 2.................................................................................................................................................1739 Removal and installation of final drive carrier assembly........................................................................................................1740 Disassembly and assembly of final drive carrier assembly........................................................................................................1742 Removal and installation of differential assembly...............................................................................................................1744 Disassembly and assembly of differential assembly...............................................................................................................1747 Steering system.....................................................................................................................................................1761 Removal and installation of steering cylinder assembly..........................................................................................................1762 Disassembly and assembly of steering cylinder assembly..........................................................................................................1763 Removal and installation of steering valve assembly.............................................................................................................1767 Disassembly and assembly of steering valve assembly.............................................................................................................1768 Brake system........................................................................................................................................................1781 Removal and installation of front wheel hub and brake assembly..................................................................................................1782 Disassembly and assembly of front wheel hub and brake assembly..................................................................................................1786 Removal and installation of final drive and rear brake assembly.................................................................................................1794 Disassembly and assembly of final drive and rear brake assembly.................................................................................................1796 Undercarriage and frame.............................................................................................................................................1811 Removal and installation of front wheel assembly................................................................................................................1812 Removal and installation of rear wheel assembly.................................................................................................................1814 Removal and installation of front suspension cylinder assembly..................................................................................................1816 Disassembly and assembly of front suspension cylinder assembly (cylinder with buffer ring)......................................................................1818 Removal and installation of king pin............................................................................................................................1821 Removal and installation of rear suspension cylinder assembly...................................................................................................1823 Disassembly and assembly of rear suspension cylinder assembly...................................................................................................1824 Hydraulic system....................................................................................................................................................1829 Removal and installation of hoist valve assembly................................................................................................................1830 Disassembly and assembly of hoist valve assembly................................................................................................................1831 Disassembly and assembly of hoist cylinder assembly.............................................................................................................1833 Body................................................................................................................................................................1837 Removal and installation of body assembly.......................................................................................................................1838 Cab and its attachments.............................................................................................................................................1843 Disassembly and assembly of operator’s seat assembly............................................................................................................1844 Removal and installation of air conditioner unit assembly.......................................................................................................1854 Electrical system...................................................................................................................................................1857 Removal and installation of engine controller assembly..........................................................................................................1858 Removal and installation of transmission controller assembly....................................................................................................1858 Removal and installation of retarder controller assembly........................................................................................................1859 Removal and installation of ABS controller assembly.............................................................................................................1859 Removal and installation of VHMS controller assembly............................................................................................................1860 90 Diagrams and drawings................................................................................................................................................ 0 Hydraulic diagrams and drawings.....................................................................................................................................1863 Power train hydraulic circuit diagram...........................................................................................................................1865 Steering and hoist hydraulic circuit diagram....................................................................................................................1866 Brake hydraulic circuit diagram.................................................................................................................................1867 Brake hydraulic circuit diagram (ASR specification).............................................................................................................1868 Brake hydraulic circuit diagram (ABS specification).............................................................................................................1869 Brake hydraulic circuit diagram (ASR and ABS specification).....................................................................................................1870 Hydraulic circuit diagram for power ladder......................................................................................................................1871 Electrical diagrams and drawings....................................................................................................................................1873 Electrical circuit diagram for outside cab (1/3)................................................................................................................1875 Electrical circuit diagram for outside cab (2/3)................................................................................................................1876 Electrical circuit diagram for outside cab (3/3)................................................................................................................1877 Electrical circuit diagram for inside cab (1/3).................................................................................................................1878 Electrical circuit diagram for inside cab (2/3).................................................................................................................1879 Electrical circuit diagram for inside cab (3/3).................................................................................................................1880 Electrical circuit diagram for VHMS (If equipped)...............................................................................................................1881 Electrical circuit diagram for ABS (Outside cab) (If equipped)..................................................................................................1882 Electrical circuit diagram for ABS (Inside cab) (If equipped)...................................................................................................1883 Electrical circuit diagram for ASR (If equipped)................................................................................................................1884 Air conditioner electrical circuit diagram (If equipped)........................................................................................................1885 Electrical circuit diagram for auto greasing (If equipped)......................................................................................................1886 Electrical circuit diagram of external power supply heater......................................................................................................1887 Connectors table and arrangement drawing........................................................................................................................1888 Electrical circuit diagram of external power supply heater......................................................................................................1889 Connectors table and arrangement drawing........................................................................................................................1890
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