Komatsu DUMP TRUCK HD785-7 Shop Manual SEN01274-41 – PDF DOWNLOAD

Description

Komatsu DUMP TRUCK HD785-7 Shop Manual SEN01274-41 – PDF DOWNLOAD

FILE DETAILS:

Komatsu DUMP TRUCK HD785-7 Shop Manual SEN01274-41 – PDF DOWNLOAD

Language : English
Pages :2094
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu DUMP TRUCK HD785-7 Shop Manual SEN01274-41 – PDF DOWNLOAD

SERIAL NUMBERS 7001 and up

1. General precautions 

Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work.

TABLE OF CONTENTS:

Komatsu DUMP TRUCK HD785-7 Shop Manual SEN01274-41 – PDF DOWNLOAD

SERIAL NUMBERS 7001 and up

Cover 1
00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword and general information 25
Safety notice 26
How to read the shop manual 31
Explanation of terms for maintenance standard 33
Handling of electric equipment and hydraulic component 35
Handling of connectors newly used for engines 44
How to read electric wire code 47
Precautions when carrying out operation 50
Method of disassembling and connecting push-pull type coupler 53
Standard tightening torque table 56
Conversion table 60
01 Specification 67
Specification and technical data 67
Specification drawing 68
Specifications 70
Weight table 73
Fuel, coolant and lubricants 74
10 Structure, function and maintenance standard 79
Engine and cooling system 79
Radiator, brake, torque converter oil cooler, aftercooler, steering, hoist oil cooler 80
Fuel system 82
Power train, Part 1 85
Power train skeleton 86
Output shaft 88
Drive shaft 90
Torque converter and transmission hydraulic piping 92
Brake cooling oil control valve (BCV) 94
Torque converter 95
Torque converter valve 103
Transmission 106
Transmission control valve 134
ECMV 136
Lubricating oil amount selector valve 143
Power train, Part 2 147
Axle 148
Differential 150
Final drive 151
Wheels 152
Steering system 155
Steering column 156
Steering linkage 157
Brake system 161
Brake piping 162
Brake valve 164
Secondary brake valve 167
Accumulator charge valve 168
Accumulator 172
Slack adjuster 174
Brake, parking brake 178
Parking brake solenoid 184
Retarder control valve 185
Exhaust brake 186
Undercarriage and frame 189
Suspension 190
Suspension cylinder 192
Rear axle support 200
Hydraulic system 203
Steering and hoist hydraulic piping 204
Steering, hoist filter (high pressure circuit) 206
Dump body control 208
Power ladder system 210
Hydraulic tank 217
Steering valve 218
Crossover relief valve 222
Steering cylinder 223
Steering control valve 224
Hoist valve 233
Dump control valve (EPC valve) 239
Hydraulic pump 242
Work equipment (Body) 247
Auto greasing system 248
Hoist cylinder 259
Cab and its attachments 261
ROPS cab 262
Air conditioner 263
Rear view monitor 272
Controller related 275
Electrical system, Part 1 277
Machine monitor system 278
Electrical system, Part 2 303
Automatic shift control system 304
External power supply heater 324
Automatic emergency steering system 326
Automatic suspension system 330
Retarder control system 333
Battery disconnector switch 346
Emergency engine stop switch 350
Dump control lever 352
Ladder control function 356
Electrical system, Part 3 359
VHMS controller related 360
ABS/ASR system 386
Komatsu traction control system (KTCS) 404
Altitude setting function 406
Speed limit function 409
Electrical system, Part 4 415
Sensors, switches 416
20 Standard value table 433
Standard service value table 433
Standard value table for engine 434
Standard value table for machine 436
30 Testing and adjusting 449
Testing and adjusting, Part 1 449
Precautions before work 451
Testing and adjusting tools list 452
Sketch of special tool 458
Testing engine speed 459
Testing air supply pressure (boost pressure) 460
Testing exhaust temperature 462
Testing exhaust gas color 464
Adjustment of valve clearance 466
Testing compression pressure 468
Testing blow-by pressure 470
Testing engine oil pressure 471
Handling of fuel system devices 472
Releasing residual pressure from fuel system 472
Testing fuel pressure 473
Reduced cylinder mode operation 474
No-injection cranking 474
Testing leakage-from pressure limiter and return rate from injector 475
Bleeding air from fuel circuit (Standard spec) 478
Bleeding air from fuel circuit (Extra low-grade fuel spec) 480
Testing the fuel circuit for leakage 482
Replacement and adjustment of fan belt 483
Testing and adjusting alternator belt tension 484
Testing and adjusting air conditioner compressor belt 485
Testing and adjusting, Part 2 487
Testing torque converter stall speed 489
Testing power train oil pressure 491
Adjusting transmission speed sensor 499
Testing and adjusting brake oil pressure 500
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas 503
Testing brake performance 511
Releasing remaining pressure in brake circuit 513
Bleeding air from brake circuit 514
Bleeding air from ASR circuit (if equipped) 516
Testing wear of front brake disc 517
Testing wear of rear brake disc 518
Method of releasing parking brake in an emergency 519
Testing and adjusting front suspension cylinder 520
Testing and adjusting rear suspension cylinder 524
Testing and adjusting front suspension cylinder (Automatic suspension specification) 528
Testing and adjusting hydraulic pressure in steering, hoist circuit 529
Testing and adjusting oil pressure in dump EPC circuit 532
Air bleeding from steering cylinder 533
Procedure for raising dump body in emergency 534
Adjusting body positioner sensor 535
Resetting method for dump body seating control 537
Adjustment of tilt lock lever of steering wheel 538
Handling of high voltage circuit of engine controller 539
Adjusting transmission controller 539
Method for emergency escape at electrical system failure 540
Testing and adjusting ladder potentiometer 544
Calibration method of ladder position 545
Testing and adjusting, Part 3 549
Setting and adjusting of devices 550
Testing and adjusting, Part 4 565
Special functions of machine monitor (EMMS) 566
Testing and adjusting, Part 5 637
Opening ORBCOMM terminal 638
VHMS controller initial setting procedure (Setting method with VHMS tool) 640
VHMS controller initial setting procedure (Setting method with KOMTRAX Plus PC tool) 665
Download data from VHMS controller (Download method with KOMTRAX Plus PC tool) 667
Precautions for replacing VHMS controller 669
Pm Clinic check sheet 675
Initial setting of payload meter 679
Setting of payload meter built in VHMS 680
40 Troubleshooting 689
Failure code table and fuse locations 689
Failure codes table 690
Fuse locations 707
General information on troubleshooting 715
Precautions before work 716
Points to remember when troubleshooting 717
Sequence of events in troubleshooting 718
Check before troubleshooting 719
Classification and procedures for troubleshooting 720
Contents of troubleshooting table 721
Connection table for connector pin numbers 723
T- branch box and T- branch adapter table 759
Troubleshooting by failure code, Part 1 763
Failure code [1500L0] Dual engagement 765
Failure code [15B0NX] Transmission oil filter: Clogging 766
Failure code [15F0KM] R → F shifting abuse 1: Mistake in operation 768
Failure code [15F0MB] R → F shifting abuse 2: Mistake in operation 768
Failure code [15F7KM] Forward clutch disk abuse: Mistake in operation or setting 769
Failure code [15G0MW] R clutch: Slipping 770
Failure code [15G7KM] Reverse clutch disk abuse: Mistake in operation or setting 772
Failure code [15H0MW] Hi clutch: Slipping 774
Failure code [15J0MW] Lo clutch: Slipping 776
Failure code [15K0MW] 1st clutch: Slipping 778
Failure code [15L0MW] 2nd clutch: Slipping 780
Failure code [15M0MW] 3rd clutch: Slipping 782
Failure code [15N0MW] 4th clutch: Slipping 784
Failure code [15SBL1] R clutch solenoid: Fill signal is ON when command current is OFF 786
Failure code [15SBMA] R clutch solenoid: Malfunction 788
Failure code [15SCL1] Hi clutch solenoid: Fill signal is ON when command current is OFF 790
Failure code [15SCMA] Hi clutch solenoid: Malfunction 793
Failure code [15SDL1] Lo clutch solenoid: Fill signal is ON when command current is OFF 794
Failure code [15SDMA] Lo clutch solenoid: Malfunction 797
Failure code [15SEL1] 1st clutch solenoid: Fill signal is ON when command current is OFF 798
Failure code [15SEMA] 1st clutch solenoid: Malfunction 801
Troubleshooting by failure code, Part 2 803
Failure code [15SFL1] 2nd clutch solenoid: Fill signal is ON when command current is OFF 806
Failure code [15SFMA] 2nd clutch solenoid: Malfunction 809
Failure code [15SGL1] 3rd clutch solenoid: Fill signal is ON when command current is OFF 810
Failure code [15SGMA] 3rd clutch solenoid: Malfunction 813
Failure code [15SHL1] 4th clutch solenoid: Fill signal is ON when command current is OFF 814
Failure code [15SHMA] 4th clutch solenoid: Malfunction 817
Failure code [15SJMA] Lockup clutch solenoid: Malfunction 818
Failure code [2F00KM] Parking brake: Mistake in operation or setting 820
Failure code [2G42ZG] Accumulator: Oil pressure reduction (Front) 823
Failure code [2G43ZG] Accumulator: Oil pressure reduction (Rear) 823
Failure code [989A00] Engine over run prevention command signal: Operating 824
Failure code [989D00] Rear section tipping over alarm: Alarm is activated 824
Failure code [989X00] Overspeed alarm: Alarm operation 825
Failure code [989Y00] Overload alarm: Speed limit function operation 825
Failure code [989Z00] Parking Brake Interlock Caution 826
Failure code [A570NX] Engine oil filter: Clogging 828
Failure code [AA10NX] Air cleaner element: Clogging 830
Failure code [AB00L4] Alternator: Failure on battery charge circuit (R terminal signal is present and engine is stopped) 832
Failure code [AB00MA] Alternator: Malfunction 834
Failure code [AB00MB] Alternator: Failure on battery charge circuit (Absence of R terminal signal and detection error) 836
Failure code [B@BAZG] Abnormal lowering of engine oil pressure: Lowering of oil pressure 838
Failure code [B@BAZK] Engine oil: Level too low 840
Failure code [B@BCNS] Engine: Overheat 842
Failure code [B@BCZK] Lowering of radiator coolant: Lowering of level 844
Failure code [B@BFZK] Lowering of fuel level 846
Failure code [B@C6NS] Brake cooling oil: Overheating (Front) 847
Failure code [B@C7NS] Brake cooling oil: Overheating (Rear) 848
Failure code [B@CENS] Overheating of torque converter oil 850
Failure code [B@GAZK] Battery electrolyte level: Lowering of level 851
Failure code [B@JANS] Steering oil temperature: Overheat 852
Troubleshooting by failure code, Part 3 855
Failure code [CA111] Engine controller (Left bank): Internal abnormality 858
Failure code [CB111] Engine controller (Right bank): Internal abnormality 860
Failure code [CA115] Abnormal engine Ne and Bkup speed sensors (Left bank): Abnormal speed sensor signal 862
Failure code [CB115] Abnormal engine Ne and Bkup speed sensors (Right bank): Abnormal speed sensor signal 863
Failure code [CA122] Charge pressure sensor too high (At left bank only): Excessively high voltage detected 864
Failure code [CA123] Charge pressure sensor too low (At left bank only): Excessively low voltage detected 866
Failure code [CA131] Throttle sensor high error (At left bank only) 868
Failure code [CA132] Throttle sensor low error (At left bank only) 871
Failure code [CA135] Oil pressure sensor too high (At left bank only): Excessively high voltage detected 872
Failure code [CA141] Oil pressure sensor too low (At left bank only): Excessively low voltage detected 874
Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected 876
Failure code [CA145] Coolant temperature sensor too low (At left bank only): Excessively low voltage detected 878
Failure code [CA153] Charge temperature sensor too high (At left bank only): Excessively high voltage detected 880
Failure code [CA154] Charge temperature sensor too low (At left bank only): Excessively low voltage detected 882
Failure code [CA187] Sensor power supply (2) abnormally low level (Left bank): Low voltage detection 884
Failure code [CB187] Sensor power supply (2) abnormally low level (Right bank): Low voltage detection 884
Failure code [CA212] Engine oil temperature sensor abnormally high level (At left bank only): High voltage detection 886
Failure code [CA213] Engine oil temperature sensor abnormally low level (At left bank only): Low voltage detection 888
Failure code [CA221] Atmospheric pressure sensor too high (At left bank only): Excessively high voltage detected 890
Failure code [CA222] Atmospheric pressure sensor too low (At left bank only): Excessively low voltage detected 892
Failure code [CA227] Sensor power source (2) too high (Left bank): Excessively high voltage detected 894
Failure code [CB227] Sensor power supply (2) abnormally high level (Right bank): High voltage detection 896
Failure code [CA234] Engine over speed (At left bank only): Excessively high speed 898
Failure code [CA238] Abnormal power source for Ne speed sensor (At left bank only): Excessively low voltage detected 900
Failure code [CB238] Abnormal power source for Ne speed sensor (At right bank only): Excessively low voltage detected 902
Failure code [CA263] Fuel temperature sensor too high (Left bank): Excessively high voltage detected 904
Failure code [CB263] Fuel temperature sensor too high (Right bank): Excessively high voltage detected 906
Failure code [CA265] Fuel temperature sensor abnormally low level (Left bank): Low voltage detection 908
Failure code [CB265] Fuel temperature sensor abnormally low level (Right bank): Low voltage detection 908
Failure code [CA271] PCV1 short circuit (Left bank): Short circuit 909
Failure code [CB271] PCV1 short circuit (Right bank): Short circuit 910
Failure code [CA272] PCV1 disconnection (Left bank): Disconnection 911
Failure code [CB272] PCV1 disconnection (Right bank): Disconnection 912
Failure code [CA273] PCV2 short circuit (Left bank): Short circuit 913
Failure code [CB273] PCV2 short circuit (Right bank): Short circuit 914
Failure code [CA274] PCV2 disconnection (Left bank): Disconnection 915
Failure code [CB274] PCV2 disconnection (Right bank): Disconnection 916
Troubleshooting by failure code, Part 4 919
Failure code [CA322] Injector No 1 (L/B No1) system disconnection or short circuit (Left bank): Disconnection, short circuit 922
Failure code [CA323] Injector No 5 (L/B No5) system disconnection or short circuit (Left bank): Disconnection, short circuit 924
Failure code [CA324] Injector No 3 (L/B No3) system disconnection or short circuit (Left bank): Disconnection, short circuit 926
Failure code [CA325] Injector No 6 (L/B No6) system disconnection or short circuit (Left bank): Disconnection, short circuit 928
Failure code [CA331] Injector No 2 (L/B No2) system disconnection or short circuit (Left bank): Disconnection, short circuit 930
Failure code [CA332] Injector No 4 (L/B No4) system disconnection or short circuit (Left bank): Disconnection, short circuit 932
Failure code [CA342] Engine controller data mismatch (Left bank): Mismatch 934
Failure code [CB342] Engine controller data mismatch (Right bank): Mismatch 934
Failure code [CA351] Abnormal injector drive circuit (Left bank): Abnormal circuit 936
Failure code [CB351] Injector drive circuit abnormality (Right bank): Circuit abnormality 938
Failure code [CA352] Sensor power supply (1) abnormally low level (Left bank): Low voltage detection 940
Failure code [CB352] Sensor power supply (1) abnormally low level (Right bank): Low voltage detection 940
Failure code [CA386] Sensor power supply (1) abnormally high level (Left bank): High voltage detection 942
Failure code [CB386] Sensor power supply (1) abnormally high level (Right bank): High voltage detection 944
Failure code [CA431] Trouble in idle validation switch 946
Failure code [CA432] Idle validation action error 950
Failure code [CA441] Power supply voltage abnormally low level (Left bank): Low voltage detection 951
Failure code [CB441] Power supply voltage abnormally low level (Right bank): Low voltage detection 951
Failure code [CA442] Power supply voltage abnormally high level (Left bank): High voltage detection 952
Failure code [CB442] Power supply voltage abnormally high level (Right bank): High voltage detection 952
Failure code [CA449] Common rail abnormally high pressure (2) (Left bank): Abnormally high pressure occurrence 953
Failure code [CB449] Common rail abnormally high pressure (2) (Right bank): Abnormally high pressure occurrence 953
Failure code [CA451] Common rail pressure sensor too high (Left bank): Excessively high voltage detected 954
Failure code [CB451] Common rail pressure sensor abnormally high level (Right bank): High voltage detection 956
Failure code [CA452] Common rail pressure sensor abnormally low level (Left bank): Abnormally low voltage detection 958
Failure code [CB452] Common rail pressure sensor abnormally low level (Right bank): Abnormally low voltage detection 958
Failure code [CA553] Common rail pressure too high (1) (Left bank): Excessively high pressure detected 959
Failure code [CB553] Common rail pressure too high (1) (Right bank): Excessively high pressure detected 960
Failure code [CA554] In-range error in common rail pressure sensor (Left bank): In-range error 961
Failure code [CB554] In-range error in common rail pressure sensor (Right bank): In-range error 961
Failure code [CA559] Loss of pressure feed from supply pump (1) (Left bank): Loss of pressure feed detected 962
Failure code [CB559] Loss of pressure feed from supply pump (1) (Right bank): Loss of pressure feed detected 966
Failure code [CA689] Abnormal engine Ne speed sensor (Left bank): Abnormal signal 970
Failure code [CB689] Abnormal engine Ne speed sensor (Right bank): Abnormal signal 972
Failure code [CA691] Intake air temperature sensor abnormally high level (At left bank only): High voltage detection 974
Failure code [CA692] Intake air temperature sensor abnormally low level (At left bank only): Low voltage detection 976
Failure code [CA731] Abnormal engine Bkup speed sensor phase (Left bank): Abnormal phase 977
Failure code [CB731] Abnormal engine Bkup speed sensor phase (Right bank): Abnormal phase 977
Troubleshooting by failure code, Part 5 979
Failure code [CA757] Loss of all engine controller data (Left bank): Loss of all data 981
Failure code [CB757] Loss of all engine controller data (Right bank): Loss of all data 981
Failure code [CA778] Abnormal engine Bkup speed sensor (Left bank): Abnormal Bkup signal 982
Failure code [CB778] Engine Bkup speed sensor abnormality (Right bank): Bkup signal error 984
Failure code [CA781] Inter-multicontroller communication error (Left bank): Communication error 986
Failure code [CB781] Inter-multicontroller communication error (Right bank): Communication error 988
Failure code [CA1257] Multicontroller distinction wiring harness key error (Left bank): Distinction error 989
Failure code [CB1257] Multicontroller distinction wiring harness key error (Right bank): Distinction error 990
Failure code [CB1548] Injector #7 (R/B #1) system disconnection/short circuit (Right bank): Disconnection/Short circuit 992
Failure code [CB1549] Injector #8 (R/B #2) system disconnection/short circuit (Right bank): Disconnection/Short circuit 994
Failure code [CB1551] Injector #10 (R/B #4) system disconnection/short circuit (Right bank): Disconnection/Short circuit 996
Failure code [CB1552] Injector #11 (R/B #5) system disconnection/short circuit (Right bank): Disconnection/Short circuit 998
Failure code [CB1553] Injector #12 (R/B #6) system disconnection/short circuit (Right bank): Disconnection/Short circuit1000
Failure code [CB1622] Injector #9 (R/B #3) system disconnection/short circuit (Right bank): Disconnection/Short circuit1002
Failure code [CA1633] KOMNET abnormality (Left bank): Communication error1004
Failure code [CA2185] Throttle sensor supply voltage high error1006
Failure code [CA2186] Throttle sensor power supply low error1008
Failure code [CA2249] Loss of pressure feed from supply pump (2) (Left bank): Loss of pressure feed detected1009
Failure code [CB2249] Loss of pressure feed from supply pump (2) (Right bank): Loss of pressure feed detected1009
Failure code [CA2555] Intake heater relay voltage low error (Left bank)1010
Failure code [CA2556] Intake heater relay voltage high error (Left bank)1012
Troubleshooting by failure code, Part 61015
Failure code [D180KA] Preheating relay output system: Disconnection1018
Failure code [D180KB] Preheating relay output system: Grounding fault1019
Failure code [D180KY] Preheating relay output system: Hot short circuit1020
Failure code [D19HKB] Stop lamp relay output system: Short circuit1022
Failure code [D1EFKA] Pre-lubrication start relay output system: Disconnection1024
Failure code [D1EFKB] Pre-lubrication start relay output system: Grounding fault1026
Failure code [D1EFKY] Pre-lubrication start relay output system: Hot short circuit1028
Failure code [D1EHKA] Engine start relay output system: Disconnection1030
Failure code [D1EHKB] Engine start relay output system: Grounding fault1032
Failure code [D1EHKY] Engine start relay output system: Hot short circuit1034
Failure code [D1EMKA] Disconnection of Parking Interlock Relay Output Circuit1036
Failure code [D1EMKB] Ground Fault of Parking Interlock Relay Output Circuit1037
Failure code [D1EMKY] Hot Short of Parking Interlock Relay Output Circuit1038
Failure code [D1ENKZ] Failure of Power Ladder Power Supply Relay Output System1039
Failure code [D1EPKA] Disconnection of Power Ladder Pump Drive Relay Output Circuit1040
Failure code [D1EPKB] Ground Fault of Power Ladder Pump Drive Relay Output Circuit1041
Failure code [D1EPKY] Hot Short of Power Ladder Pump Drive Relay Output Circuit1042
Failure code [D1EQKA] Disconnection of Power Ladder Buzzer Relay Output Circuit1043
Failure code [D1EQKB] Ground Fault of Power Ladder Buzzer Relay Output Circuit1044
Failure code [D1EQKY] Hot Short of Power Ladder Buzzer Relay Output Circuit1045
Failure code [D1ERKA] Open Circuit in Power Ladder Raise Solenoid Relay Output Circuit1046
Failure code [D1ERKB] Ground Fault of Power Ladder Raise Solenoid Relay Output Circuit1047
Failure code [D1ERKY] Hot Short in Power Ladder Raise Solenoid Relay Output Circuit1048
Failure code [D1ESKA] Open Circuit in Power Ladder Lower Solenoid Relay Output Circuit1049
Failure code [D1ESKB] Ground Fault of Power Ladder Lower Solenoid Relay Output Circuit1050
Failure code [D1ESKY] Hot Short in Power Ladder Lower Solenoid Relay Output Circuit1051
Failure code [DAF9KM] Wrong connection of connector1052
Failure code [DAFRKR] Abnormal CAN communication (machine monitor): Abnormal communication1053
Failure code [DAQ0KK] Transmission controller direct power supply: Lowering of power supply voltage1054
Failure code [DAQ0KT] Transmission controller nonvolatile memory: Abnormality in controller1056
Failure code [DAQ2KK] Transmission controller solenoid power supply: Power supply voltage too low1058
Failure code [DAQ9KQ] Transmission controller: Disagreement of model selection1060
Failure code [DAQRKR] Abnormality in CAN communication (Transmission)1061
Failure code [DAQRMA] Transmission controller option setting: Malfunction1066
Failure code [DB10KT] Retarder controller nonvolatile memory: Abnormality in controller1066
Failure code [DB12KK] Retarder controller solenoid power supply: Power supply system trouble1067
Failure code [DB13KK] Retarder controller battery direct power supply: Power supply voltage too low1069
Failure code [DB19KQ] Disagreement of model selection (Retarder controller)1071
Failure code [DB1RKR] CAN communication (retarder controller): Communication disabled1072
Failure code [DB1RMA] Disagreement of option setting (Retarder controller)1076
Failure code [DB2RKR] CAN communication (engine controller): Communication disabled1077
Failure code [dB2RKR] CAN communication (engine controller): Communication disabled1083
Failure code [DBB0KK] or VHMS_LED display: “n9” -> “01” VHMS controller: Low power supply voltage (input)1090
Failure code [DBB0KQ] (or VHMS_LED display: “nF” -> “11”) VHMS controller: Disagreement of model selection signals1092
Failure code [DBB3KK] (or VHMS_LED display: “n9” -> “05”) VHMS controller battery power supply: Low power supply voltage (input)1094
Failure code [DBB5KP] (or VHMS_LED display: “n9” -> “04”) VHMS controller 5 V power supply output: Low output voltage1096
Failure code [DBB6KP] (or VHMS_LED display: “n9” -> “02”) VHMS controller 24 V power supply output: Low output voltage1098
Failure code [DBB7KP] (or VHMS_LED display: “n9” -> “03”) VHMS controller 12 V power supply output: Low output voltage1100
Failure code [DBBQKR] (or VHMS_LED display: “n8” -> “02”) VHMS controller CAN communication: Defective communication (Abnormality in target component system)1101
Failure code [DBC0KT] Abnormality of Non-volatile Memory1102
Failure code [DBC2KK] ABS controller solenoid power supply: Power supply system trouble1104
Failure code [DBC2KK] Solenoid Power Supply: Low Voltage1106
Failure code [DBC3KK] ABS controller battery direct power supply: Power supply voltage too low1108
Failure code [DBC3KK] Direct Battery Power Supply: Low Voltage1110
Failure code [DBC9KQ] Disagreement of model selection (ABS controller)1112
Failure code [DBCRKR] Abnormality in CAN communication (ABS)1113
Failure code [DBCRMA] Disagreement of option setting (ABS controller) 1117
Failure code [DBG2KK] Solenoid power supply: Low voltage1118
Failure code [DBG3KK] Battery direct power supply: Low voltage1120
Failure code [DBG9KQ] Model selection signal: Abnormal1122
Failure code [DDD7KX] Trouble in travel speed setting switch system: Out of input signal range1124
Failure code [DDD8KA] ARSC system switch system: Disconnection (If equipped)1126
Failure code [DDD8KB] ARSC system switch system: Short circuit (If equipped)1128
Failure code [DDD9KA] ABS system switch system: Disconnection1130
Failure code [DDD9KB] ABS system switch system: Short circuit1132
Failure code [DDDAKA] ASR system switch: Disconnection1134
Failure code [DDDAKB] ASR system switch: Short circuit1136
Failure code [DDDGL4] Failure of ladder manual operation switch CH1 (inside cab) system1138
Failure code [DDDHL4] Failure of ladder manual operation switch CH2( outside cab) system1140
Failure code [DDE2KB] Engine oil pressure switch error: Grounding fault1142
Failure code [DDE2L6] Engine oil pressure switch error: Disconnection or hot short circuit1144
Failure code [DDP6L4] Service brake pressure switch trouble (Rear) 1146
Failure code [DDTHKA] Hi clutch fill switch: Disconnection 1148
Failure code [DDTJKA] Lo clutch fill switch: Disconnection1150
Failure code [DDTKKA] 1st clutch fill switch: Disconnection 1152
Failure code [DDTLKA] 2nd clutch fill switch: Disconnection1154
Failure code [DDTMKA] 3rd clutch fill switch: Disconnection1156
Failure code [DDTNKA] R clutch fill switch: Disconnection1158
Failure code [DDTPKA] 4th clutch fill switch: Disconnection1160
Failure code [DDU1KA] Open Circuit in Parking Brake Operation Input Circuit1162
Failure code [DF10KA] Gear shift lever: Disconnection1163
Failure code [DF10KB] Gear shift lever: Short circuit1166
Failure code [DGE5KX] or VHMS_LED display: “n4” -> “01” Atmospheric temperature sensor: Out of input signal range1170
Failure code [DGF1KX] Transmission oil temperature sensor: Out of input signal range1172
Failure code [DGR2KB] Trouble in retarder oil temperature sensor (rear wheel) system (Disconnection and short circuit)1174
Failure code [DGR2KZ] Trouble in retarder oil temperature sensor (rear wheel) system (Ground fault)1176
Failure code [DGR4KB] Trouble in retarder oil temperature sensor (front wheel) system (Disconnection and short circuit)1177
Failure code [DGR4KZ] Trouble in retarder oil temperature sensor (front wheel) system (Ground fault)1178
Failure code [DGR6KX] Steering oil temperature sensor: Input signal out of range1180
Failure code [DGT1KX] Torque converter oil temperature sensor: Out of input signal range1182
Troubleshooting by failure code, Part 71185
Failure code [DGT5KA] (or VHMS_LED display: “n3” o “12”) Left bank exhaust temperature sensor system (Front): Disconnection1187
Failure code [dGT5KA] (or VHMS_LED display: “n3” o “22”) Left bank exhaust temperature sensor system (Rear): Disconnection1190
Failure code [DGT5KB] (or VHMS_LED display: “n3” o “11”) Left bank exhaust temperature sensor system (Front): Short circuit1193
Failure code [dGT5KB] (or VHMS_LED display: “n3” o “21”) Left bank exhaust temperature sensor system (Rear): Short circuit1196
Failure code [DGT6KA] (or VHMS_LED display: “n3” o “24”) Right bank exhaust temperature sensor system (Front): Disconnection1199
Failure code [dGT6KA] (or VHMS_LED display: “n3” o “26”) Right bank exhaust temperature sensor system (Rear): Disconnection1202
Failure code [DGT6KB] (or VHMS_LED display: “n3” o “23”) Right bank exhaust temperature sensor system (Front): Short circuit1205
Failure code [dGT6KB] (or VHMS_LED display: “n3” o “25”) Right bank exhaust temperature sensor system (Rear): Short circuit1208
Failure code [DHE5KB] or VHMS_LED display: “n3” o “32” Blow-by pressure sensor: Short circuit1211
Failure code [DHE5KY] or VHMS_LED display: “n3” o “31” Blow-by pressure sensor: Short circuit with power supply line1214
Failure code [DHP4KY] or VHMS_LED display: “n5” o “44” Short circuit in suspension pressure sensor system (Front right)1216
Failure code [DHP4KZ] or VHMS_LED display: “n5” o “43” Disconnection or ground fault in suspension pressure sensor system(Front right)1218
Failure code [DHP5KY] or VHMS_LED display: “n5” o “54” Short circuit in suspension pressure sensor system (Front left)1220
Failure code [DHP5KZ] or VHMS_LED display: “n5” o “53” Disconnection or ground fault in suspension pressure sensor system(Front left)1222
Failure code [DHP6KA] Suspension pressure sensor system: Disconnection (Right rear)1224
Failure code [DHP6KX] Failure in suspension pressure sensor system trouble: Out of input signal range (Right rear)1225
Failure code [DHP6KY] or VHMS_LED display: “n5” o “64” Suspension pressure sensor system: Short circuit (Right rear)1228
Failure code [DHP6KZ] or VHMS_LED display: “n5” o “63” Suspension pressure sensor system: Disconnection or ground fault (Right rear)1230
Failure code [DHP7KA] Suspension pressure sensor system: Disconnection (Left rear)1232
Failure code [DHP7KX] Failure in suspension pressure sensor system trouble: Out of input signal range (Left rear)1233
Failure code [DHP7KY] or VHMS_LED display: “n5” o “74” Suspension pressure sensor system: Short circuit (Left rear)1236
Failure code [DHP7KZ] or VHMS_LED display: “n5” o “73” Suspension pressure sensor system: Disconnection or ground fault (Left rear)1238
Failure code [DHT5KX] Torque converter oil pressure sensor: Out of input signal range1240
Failure code [DHT5L6] Torque converter oil pressure sensor: Disagreement of run and stop condition with signal1242
Failure code [DHU2KX] Front accumulator oil pressure sensor: Out of input signal range1244
Failure code [DHU3KX] Rear accumulator oil pressure sensor: Out of input signal range1246
Failure code [DHU6KX] Trouble in ABS control valve pressure sensor (Front right)1248
Failure code [DHU7KX] Trouble in ABS control valve pressure sensor (Front left)1250
Failure code [DHU8KX] Trouble in ABS control valve pressure sensor (Front right)1252
Failure code [DHU9KX] Trouble in ABS control valve pressure sensor (Front right)1254
Failure code [DHUTKX] Trouble in ABS cut valve pressure sensor1256
Failure code [DJF1KA] Fuel level sensor: Disconnection1258
Failure code [DK30KX] Steering angle potentiometer: Trouble (Disconnection)1260
Failure code [DK51L5] Retarder lever potentiometer: Potentiometer signal is inconsistent with swich signal1261
Failure code [DK52KX] Failure in hoist lever potentiometer 1: Out of input signal range1264
Failure code [DK53L8] Failure in hoist lever potentiometer 2: Disagreement of analog signal1266
Failure code [DK54KX] Body positioner sensor: Out of input signal range1268
Failure code [DK5VKX] Abnormality of Power Ladder Position Input Signal (Out of Range)1270
Failure code [DK5VMA] Power Ladder System Abnormality1272
Failure code [DK60KX] Trouble in acceleration sensor (out of range)1274
Failure code [DKD0L6] Failure in steering speed sensor1276
Failure code [DKH0KX] Clinometer sensor signal out of range1278
Failure code [DKH1KX] (or VHMS_LED display: “n4″o”33”) Abnormality in clinometer sensor1280
Failure code [DLF1KA] Transmission input shaft speed sensor: Disconnection1282
Failure code [DLF1LC] Transmission input shaft speed sensor: Disagreement of revolution speed signal1284
Failure code [DLF2KA] Transmission intermediate shaft speed sensor: Disconnection1286
Failure code [DLF2LC] Transmission intermediate shaft speed sensor: Disagreement of revolution speed signal1288
Troubleshooting by failure code, Part 81291
Failure code [DLF6KA] Disconnection in wheel speed sensor (Front right)1294
Failure code [DLF6L3] Trouble in wheel speed sensor (Front right)1296
Failure code [DLF7KA] Disconnection in wheel speed sensor (Front left)1298
Failure code [DLF7L3] Trouble in wheel speed sensor (Front left)1300
Failure code [DLF8KA] Wheel speed sensor: Disconnection (Rear right)1302
Failure code [DLF8L3] Wheel speed sensor: Disconnection (Rear right)1304
Failure code [DLF8LC] Wheel speed sensor: Trouble (Rear right)1306
Failure code [DLF8MA] Wheel speed sensor: Disconnection (Rear right)1306
Failure code [DLF9KA] Wheel speed sensor: Disconnection (Rear left)1308
Failure code [DLF9L3] Wheel speed sensor: Trouble (Rear left)1310
Failure code [DLF9LC] Wheel speed sensor: Trouble (Rear left)1312
Failure code [DLF9MA] Wheel speed sensor: Disconnection (Rear left)1312
Failure code [DLT3KA] Transmission output shaft speed sensor: Disconnection1314
Failure code [DLT3LC] Transmission output shaft speed sensor: Disagreement of revolution speed signal1316
Failure code [DLT4KA] Transmission output shaft speed sensor: Disconnection1318
Failure code [DLT4MA] Transmission output shaft speed sensor: Disconnection1320
Failure code [DUM7KY] Pre-lubrication operation lamp output abnormality: Hot short circuit1322
Failure code [DUM7KZ] Pre-lubrication operation lamp output abnormality: Disconnection or grounding fault1324
Failure code [DUM9KZ] Failure of power ladder indicator system1326
Failure code [DV00KB] Buzzer output: Short circuit1328
Failure code [DW2AKA] Main pressure variable valve output: Disconnection1330
Failure code [DW2AKB] Main pressure variable valve output circuit: Ground fault1332
Failure code [DW2AKY] Main pressure variable valve output circuit: Hot short1334
Failure code [DW2AL1] Main pressure variable valve: Defective reset1336
Failure code [DW2ALH] Main pressure variable valve: Malfunction1338
Failure code [DW2BKA] Main oil level selector valve output: Disconnection1339
Failure code [DW2BKB] Main oil level selector valve output circuit: Ground fault1340
Failure code [DW2BKY] Main oil level selector valve output circuit: Hot short1342
Failure code [DW2BL1] Main oil level selector valve: Defective reset1344
Failure code [DW2BLH] Main oil level selector valve: Malfunction1346
Failure code [DW2CKA] Transmission lubrication variable valve output: Disconnection1347
Failure code [DW2CKB] Transmission lubrication variable valve outputcircuit: Ground fault1348
Failure code [DW2CKY] Transmission lubrication variable valve output circuit: Hot short1350
Failure code [DW2CL1] Transmission lubrication variable valve: Defective reset1352
Failure code [DW2CLH] Transmission lubrication variable valve: Malfunction1354
Failure code [DW35KZ] Failure in output system of auto suspension solenoid 1: Disconnection or short circuit1356
Failure code [DW36KZ] Failure in output system of auto suspension solenoid 2: Disconnection or short circuit1358
Failure code [DW71KZ] Exhaust brake output system trouble (Disconection/Ground fault/Hot short)1360
Failure code [DW72KZ] Kick-out solenoid output system trouble: Disconnection or short circuit1362
Failure code [DW73KZ] Failure in hoist select valve output system: Disconnection or short circuit1364
Failure code [DW78KZ] Brake cooling valve (BCV) (rear wheel) output system trouble: Disconnection or short circuit1366
Failure code [DWNBK4] ASR shut-off valve: Trouble (Valve keeps operating)1368
Failure code [DWNBKA] ASR shut-off valve output circuit: Disconnection1370
Failure code [DWNBKB] ASR shut-off valve output circuit: Ground fault1372
Failure code [DWNBKY] ASR shut-off valve output circuit: Short circuit1374
Failure code [DWNBMA] ASR shut-off valve: Trouble (Valve does not operate)1375
Failure code [DWNDKZ] Trouble in ABS cut-off valve (Front) system1376
Failure code [DWNDMA] Defective ABS cut-off valve (Front)1378
Failure code [DWNEKZ] Trouble in ABS cut-off valve (Rear) system1380
Failure code [DWNEMA] Defective ABS cut-off valve (Rear)1382
Failure code [DWNLKA] Open Circuit in Power Ladder Shock Reducing Solenoid Output Circuit1384
Failure code [DWNLKB] Ground Fault of Power Ladder Shock Reducing Solenoid Output Circuit1385
Failure code [DWNLKY] Hot Short in Power Ladder Shock Reducing Solenoid Output Circuit1386
Troubleshooting by failure code, Part 91389
Failure code [DX11K4] Rear brake proportional pressure reducing solenoid valve: Out of control1392
Failure code [DX11KA] Rear brake proportional pressure reducing solenoid valve output circuit: Disconnection1394
Failure code [DX11KB] Rear brake proportional pressure reducing solenoid valve: Short circuit1395
Failure code [DX11KY] Rear brake proportional pressure reducing solenoid valve: Short circuit to power source line1396
Failure code [DX11MA] Rear brake proportional pressure reducing solenoid valve: Malfunction1397
Failure code [DX12K4] Front brake proportional pressure reducing solenoid valve: Out of control1398
Failure code [DX12KA] Front brake proportional pressure reducing solenoid valve output circuit: Disconnection1400
Failure code [DX12KB] Front brake proportional pressure reducing solenoid valve: Short circuit1401
Failure code [DX12KY] Front brake proportional pressure reducing solenoid valve: Short circuit to power source line1402
Failure code [DX12MA] Front brake proportional pressure reducing solenoid valve: Malfunction1403
Failure code [DX13KA] Output circuit of hoist EPC valve: Disconnection1404
Failure code [DX13KB] Output circuit of hoist EPC valve: Short circuit1406
Failure code [DX13KY] Output circuit of hoist EPC valve: Short circuit with power source line1408
Failure code [DX17K4] ASR proportional pressure reducing solenoid valve (right): Trouble (Valve keeps operating)1410
Failure code [DX17KA] ASR proportional pressure reducing solenoid valve (right) output circuit: Disconnection1412
Failure code [DX17KB] ASR proportional pressure reducing solenoid valve (right) output circuit: Ground fault1414
Failure code [DX17KY] ASR proportional pressure reducing solenoid valve (right) output circuit: Short circuit1416
Failure code [DX17MA] ASR proportional pressure reducing solenoid valve (right): Trouble (Valve does not operate)1417
Failure code [DX18K4] ASR proportional pressure reducing solenoid valve (left): Trouble (Valve keeps operating)1418
Failure code [DX18KA] ASR proportional pressure reducing solenoid valve (left) output circuit: Disconnection1420
Failure code [DX18KB] ASR proportional pressure reducing solenoid valve (left) output circuit: Ground fault1422
Failure code [DX18KY] ASR proportional pressure reducing solenoid valve (left) output circuit: Short circuit1424
Failure code [DX18MA] ASR proportional pressure reducing solenoid valve (left): Trouble (Valve does not operate)1425
Failure code [DX21KA] Disconnection in ABS control valve output circuit (Front right)1426
Failure code [DX21KB] Ground fault in ABS control valve output circuit (Front right)1427
Failure code [DX21KY] Hot short in ABS control valve output circuit (Front right)1428
Failure code [DX21MA] Defective ABS control valve (Front right)1429
Failure code [DX22KA] Disconnection in ABS control valve output circuit (Front left)1430
Failure code [DX22KB] Ground fault in ABS control valve output circuit (Front left)1431
Failure code [DX22KY] Hot short in ABS control valve output circuit (Front left)1432
Failure code [DX22MA] Defective ABS control valve (Front left)1433
Failure code [DX23KA] Disconnection in ABS control valve output circuit (Rear right)1434
Failure code [DX23KB] Ground fault in ABS control valve output circuit (Rear right)1435
Failure code [DX23KY] Hot short in ABS control valve output circuit (Rear right)1436
Failure code [DX23MA] Defective ABS control valve (Rear right)1437
Failure code [DX24KA] Disconnection in ABS control valve output circuit (Rear left)1438
Failure code [DX24KB] Ground fault in ABS control valve output circuit (Rear left)1439
Failure code [DX24KY] Hot short in ABS control valve output circuit (Rear left)1440
Failure code [DX24MA] Defective ABS control valve (Rear left)1441
Failure code [DX25MA] Defective ABS front wheel system control valve1442
Failure code [DX26MA] Defective ABS rear wheel system control valve1442
Troubleshooting by failure code, Part 101445
Failure code [DXH1KA] Lockup clutch solenoid output circuit: Disconnection1448
Failure code [DXH1KB] Lockup clutch solenoid output circuit: Short circuit1450
Failure code [DXH1KY] Lockup clutch solenoid output circuit: Short circuit to power supply line1452
Failure code [DXH2KA] Hi clutch solenoid output circuit: Disconnection1454
Failure code [DXH2KB] Hi clutch solenoid output circuit: Short circuit1456
Failure code [DXH2KY] Hi clutch solenoid output circuit: Short circuit to power supply line1458
Failure code [DXH3KA] Lo clutch solenoid output circuit: Disconnection1462
Failure code [DXH3KB] Lo clutch solenoid output circuit: Short circuit1464
Failure code [DXH3KY] Lo clutch solenoid output circuit: Short circuit in power supply line1466
Failure code [DXH4KA] 1st clutch solenoid output circuit: Disconnection1470
Failure code [DXH4KB] 1st clutch solenoid output circuit: Short circuit1472
Failure code [DXH4KY] 1st clutch solenoid output circuit: Short circuit to power supply line1474
Failure code [DXH5KA] 2nd clutch solenoid output circuit: Disconnection1478
Failure code [DXH5KB] 2nd clutch solenoid output circuit: Short circuit1480
Failure code [DXH5KY] 2nd clutch solenoid output circuit: Short circuit in power supply line1482
Failure code [DXH6KA] 3rd clutch solenoid output circuit: Disconnection1486
Failure code [DXH6KB] 3rd clutch solenoid output circuit: Short circuit1488
Failure code [DXH6KY] 3rd clutch solenoid output circuit: Short circuit to power supply line1490
Failure code [DXH7KA] R clutch solenoid output circuit: Disconnection1494
Failure code [DXH7KB] R clutch solenoid output circuit: Short circuit1496
Failure code [DXH7KY] R clutch solenoid output circuit: Short circuit to power supply line1498
Failure code [DXHHKA] 4th clutch solenoid output circuit: Disconnection1500
Failure code [DXHHKB] 4th clutch solenoid output circuit: Short circuit1502
Failure code [DXHHKY] 4th clutch solenoid output circuit: Short circuit to power supply line1504
Failure code [F@BBZL] or VHMS_LED display: “n3” → “38” Blow-by pressure: High error1507
Failure code [F@BYNS] (or VHMS_LED display “n3” → “61”) Left front exhaust temperature sensor (1): Exhaust temperature abnormal rise1508
Failure code [f@BYNS] (or VHMS_LED display “n3” → “71”) Left rear exhaust temperature sensor (1): Exhaust temperature abnormal rise1510
Failure code [F@BZNS] (or VHMS_LED display “n3” → “81”) Right front exhaust temperature sensor (1): Exhaust temperature abnormal rise1512
Failure code [f@BZNS] (or VHMS_LED display “n3” → “91”) Right rear exhaust temperature sensor (1): Exhaust temperature abnormal rise1514
Failure code [F@BYNR] (or VHMS_LED display “n3” → “62”) Left front exhaust temperature sensor (2): Exhaust temperature abnormal rise1516
Failure code [f@BYNR] (or VHMS_LED display “n3” → “72”) Left rear exhaust temperature sensor (2): Exhaust temperature abnormal rise1518
Failure code [F@BZNR] (or VHMS_LED display “n3” → “82”) Right front exhaust temperature sensor (2): Exhaust temperature abnormal rise1520
Failure code [f@BZNR] (or VHMS_LED display “n3” → “92”) Right rear exhaust temperature sensor (2): Exhaust temperature abnormal rise1522
Troubleshooting of electrical system (E-mode)1525
Before troubleshooting of electric system1527
Contents of troubleshooting table1528
E-1 Engine does not start1529
E-2 Automatic preheating does not operate1532
E-3 Machine monitor does not display all, when starting switch is turned ON1536
E-4 Machine monitor does not operate when starting switch is OFF1538
E-5 Alarm buzzer does not sound1540
E-6 Alarm buzzer does not stop sounding1542
E-7 Gauges of machine monitor, caution lamps or character display section do not display properly1543
E-8 A selection of the display in character display section cannot be changed1545
E-9 Power mode selecting function does not operate properly1548
E-10 AISS function does not operate properly1549
E-11 Seat belt caution lamp does not display properly1550
E-12 Turn signal lamp or turning lamp (hazard lamp) do not work properly1551
E-13 Night illumination (lighting) does not work properly1554
E-14 Emergency steering does not operate1566
E-15 Hoist lever does not operate normally1580
E-16 Power supply system (Air conditioner does not operate)1582
E-17 Compressor and refrigerant system (Air is not cooled)1584
E-18 Blower motor system (Air does not come out or air flow is abnormal)1586
E-19 Ladder cannot be lowered with operation switch outside cab1588
E-20 Ladder cannot be lowered with operation switch inside cab1589
E-21 Ladder continues lowering1590
E-22 Ladder cannot be raised with operation switch outside cab1591
E-23 Ladder cannot be lowered with operation switch inside cab1592
E-24 Ladder continues rising1593
E-25 Buzzer does not sound when power ladder is operated1594
E-26 Power ladder pump does not operate1595
Troubleshooting of hydraulic and mechanical system (H-mode)1597
Contents of troubleshooting table1599
H-1 Machine does not start1600
H-2 Machine does not travel smoothly (hunting)1602
H-3 Lockup cannot be cancelled1602
H-4 Excessive shock when starting or shifting excessive1603
H-5 Transmission does not shift up1604
H-6 Machine lacks power or speed when traveling1606
H-7 Time lag is excessive when starting or shifting gear1610
H-8 Torque converter oil temperature is high1612
H-9 Torque converter oil pressure is low1613
H-10 Front brake is ineffective1614
H-11 Rear brake is ineffective1615
H-12 Steering wheel is heavy1616
H-13 Steering wheel does not work1617
H-14 Steering wheel vibrates1618
H-15 Dump body lifting speed is slow1619
H-16 Dump body does not work1620
H-17 Excessive hydraulic drift of dump body1621
H-18 Power ladder does not move or its speed is low1622
Troubleshooting of engine (S-mode)1625
Method of using troubleshooting charts1627
S-1 Starting performance is poor1630
S-2 Engine does not start1631
S-3 Engine does not pick up smoothly1634
S-4 Engine stops during operations1635
S-5 Engine does not rotate smoothly1636
S-6 Engine lacks output (or lacks power)1637
S-7 Exhaust smoke is black (incomplete combustion)1639
S-8 Oil consumption is excessive (or exhaust smoke is blue)1640
S-9 Oil becomes contaminated quickly1641
S-10 Fuel consumption is excessive1642
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1643
S-12 Oil pressure drops1644
S-13 Oil level rises (Entry of coolant or fuel)1645
S-14 Coolant temperature becomes too high (overheating)1646
S-15 Abnormal noise is made1647
S-16 Vibration is excessive1648
50 Disassembly and assembly1651
General information on disassembly and assembly1651
Precautions before work1652
How to read this manual1653
Coating materials list1655
Special tool list1658
Sketches of special tools1665
Engine and cooling system1701
Removal and installation of fuel supply pump assembly1702
Removal and installation of fuel injector assembly1704
Removal and installation of cylinder head assembly1705
Removal and installation of engine hood assembly1718
Removal and installation of radiator assembly1719
Removal and installation of engine assembly1728
Removal and installation of engine front oil seal1733
Removal and installation of engine rear oil seal1736
Power train, Part 11741
Removal and installation of front drive shaft1742
Removal and installation of rear drive shaft assembly1744
Removal and installation of output shaft assembly1745
Disassembly and assembly of damper assembly1751
Removal and installation of torque converter and transmission assemblies1753
Disconnection and connection of torque converter assembly and transmission assembly1756
Disassembly and assembly of torque converter and PTO assembly1767
Disassembly and assembly of transmission assembly1785
Power train, Part 21825
Removal and installation of final drive carrier assembly1826
Disassembly and assembly of final drive carrier assembly1828
Removal and installation of differential assembly1830
Disassembly and assembly of differential assembly1833
Steering system1853
Removal and installation of steering cylinder assembly1854
Disassembly and assembly of steering cylinder assembly1855
Removal and installation of steering valve assembly1859
Disassembly and assembly of steering valve assembly1860
Brake system1873
Removal and installation of front wheel hub and brake assembly1874
Disassembly and assembly of front wheel hub and brake assembly1878
Removal and installation of final drive and rear brake assembly1886
Disassembly and assembly of final drive and rear brake assembly1888
Undercarriage and frame1929
Removal and installation of front wheel assembly1930
Removal and installation of rear wheel assembly1932
Removal and installation of front suspension cylinder assembly1934
Disassembly and assembly of front suspension cylinder assembly (cylinder with buffer ring)1936
Removal and installation of king pin1939
Removal and installation of rear suspension cylinder assembly1941
Disassembly and assembly of rear suspension cylinder assembly1942
Hydraulic system1947
Removal and installation of hoist valve assembly1948
Disassembly and assembly of hoist valve assembly1949
Disassembly and assembly of hoist cylinder assembly1951
Body1955
Removal and installation of body assembly1956
Cab and its attachments1961
Disassembly and assembly of operator’s seat assembly1962
Removal and installation of air conditioner unit assembly1972
Electrical system1975
Removal and installation of engine controller assembly1976
Removal and installation of transmission controller assembly1976
Removal and installation of retarder controller assembly1977
Removal and installation of ABS controller assembly1977
Removal and installation of VHMS controller assembly1978
80 Appendix1981
Air conditioner1981
Precautions before work1983
Precautions for refrigerant1984
Configuration and function of refrigeration cycle1985
Outline of refrigeration cycle1986
Air conditioner unit1988
Air conditioner control panel1994
Troubleshooting procedure1996
Circuit diagram and arrangement of connector pins1998
System diagram2000
Details of air conditioner unit2001
Inspection by self-diagnosis function2002
Testing temperature control system2003
Testing vent (mode) changeover2004
Testing FRESH/RECIRC air changeover2006
Check evaporator temperature sensor2008
Testing relays2009
Troubleshooting chart 12010
Troubleshooting chart 22011
Information in troubleshooting table2013
Troubleshooting for power supply system (Air conditioner does not operate)2014
Troubleshooting for compressor and refrigerant system (Air is not cooled)2017
Troubleshooting for blower motor system (No air comes out or air flow is abnormal)2021
Troubleshooting for temperature control2024
Troubleshooting for vent (mode) changeover2026
Troubleshooting for FRESH/RECIRC air changeover2028
Troubleshooting with gauge pressure2031
Connection of service tool2033
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit2034
Handling of compressor oil2036
90 Diagrams and drawings2039
Hydraulic diagrams and drawings2039
Power train hydraulic circuit diagram2041
Steering and hoist hydraulic circuit diagram2043
Brake hydraulic circuit diagram2045
Brake hydraulic circuit diagram (ASR specification)2047
Brake hydraulic circuit diagram (ABS specification)2049
Brake hydraulic circuit diagram (ASR and ABS specification)2051
Hydraulic circuit diagram for power ladder2053
Electrical diagrams and drawings2055
Electrical circuit diagram for outside cab2057
Electrical circuit diagram for inside cab2065
Electrical circuit diagram for VHMS2077
Electrical circuit diagram for ABS(Outside cab)2079
Electrical circuit diagram for ABS(Inside cab)2081
Electrical circuit diagram for ASR2083
Air conditioner electrical circuit diagram2085
Electrical circuit diagram for power ladder2087
Electrical circuit diagram for auto greasing2089
Electrical circuit diagram of external power supply heater2090
Connectors table and arrangement drawing2091

S.M 30/12/24