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KOMATSU HD785-7 DUMP TRUCK SERVICE REPAIR MANUAL – PDF DOWNLOAD
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- KOMATSU HD785-7 DUMP TRUCK SERVICE REPAIR MANUAL
- SERIAL NUMBERS A10001 & UP
- PUBLICATION NUMBER:CEBM019012
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Description
KOMATSU HD785-7 DUMP TRUCK SERVICE REPAIR MANUAL
KOMATSU HD785-7 DUMP TRUCK SERVICE REPAIR MANUAL – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU HD785-7 DUMP TRUCK SERVICE REPAIR 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. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and 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. 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.
30. 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.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The ΒS modeΒ 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.
50. 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. Diagrams and drawings (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 HD785-7 DUMP TRUCK SERVICE REPAIR MANUAL
COVER................................................................................................................................................................... 1 00 Index and foreword................................................................................................................................................... 3 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........................................................................................................................................................ 65 Specification and technical data.................................................................................................................................... 65 Specification drawing........................................................................................................................................... 66 Specifications.................................................................................................................................................. 68 Weight table.................................................................................................................................................... 71 Fuel, coolant and lubricants.................................................................................................................................... 72 10 Structure, function and maintenance standard......................................................................................................................... 77 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 Hydraulic tank.................................................................................................................................................. 208 Steering valve.................................................................................................................................................. 209 Crossover relief valve.......................................................................................................................................... 213 Steering cylinder............................................................................................................................................... 214 Steering control valve.......................................................................................................................................... 215 Hoist valve..................................................................................................................................................... 224 Dump control valve (EPC valve).................................................................................................................................. 230 Hydraulic pump.................................................................................................................................................. 234 Work equipment (Body)............................................................................................................................................... 239 Auto greasing system............................................................................................................................................ 240 Hoist cylinder.................................................................................................................................................. 251 Cab and its attachments............................................................................................................................................. 253 ROPS cab........................................................................................................................................................ 254 Air conditioner................................................................................................................................................. 255 Rear view monitor............................................................................................................................................... 264 Controller related.............................................................................................................................................. 267 Electrical system, Part 1........................................................................................................................................... 269 Machine monitor system.......................................................................................................................................... 270 Electrical system, Part 2........................................................................................................................................... 295 Automatic shift control system.................................................................................................................................. 296 Automatic emergency steering system............................................................................................................................. 316 Automatic suspension system..................................................................................................................................... 320 Retarder control system......................................................................................................................................... 323 Battery disconnector switch..................................................................................................................................... 336 Dump control lever.............................................................................................................................................. 340 Electrical system, Part 3........................................................................................................................................... 345 VHMS controller related......................................................................................................................................... 346 ABS/ASR system.................................................................................................................................................. 372 Altitude setting function....................................................................................................................................... 390 Electrical system, Part 4........................................................................................................................................... 395 Sensors, switches............................................................................................................................................... 396 20 Standard value table................................................................................................................................................. 415 Standard service value table........................................................................................................................................ 415 Standard value table for engine................................................................................................................................. 416 Standard value table for machine................................................................................................................................ 418 30 Testing and adjusting................................................................................................................................................ 431 Testing and adjusting, Part 1....................................................................................................................................... 431 Testing and adjusting tools list................................................................................................................................ 433 Testing engine speed............................................................................................................................................ 439 Testing air supply pressure (boost pressure).................................................................................................................... 440 Testing exhaust temperature..................................................................................................................................... 442 Testing exhaust gas color....................................................................................................................................... 444 Adjustment of valve clearance................................................................................................................................... 446 Testing compression pressure.................................................................................................................................... 448 Testing blow-by pressure........................................................................................................................................ 450 Testing engine oil pressure..................................................................................................................................... 451 Handling of fuel system devices................................................................................................................................. 452 Releasing residual pressure from fuel system.................................................................................................................... 452 Testing fuel pressure........................................................................................................................................... 453 Reduced cylinder mode operation................................................................................................................................. 454 No-injection cranking........................................................................................................................................... 454 Testing leakage-from pressure limiter and return rate from injector............................................................................................. 455 Bleeding air from fuel circuit (Standard spec.)................................................................................................................. 458 Bleeding air from fuel circuit (Extra low-grade fuel spec.)..................................................................................................... 460 Testing the fuel circuit for leakage............................................................................................................................ 462 Replacement and adjustment of fan belt.......................................................................................................................... 463 Testing and adjusting alternator belt tension................................................................................................................... 464 Testing and adjusting air conditioner compressor belt........................................................................................................... 465 Testing and adjusting, Part 2....................................................................................................................................... 467 Testing torque converter stall speed............................................................................................................................ 469 Testing power train oil pressure................................................................................................................................ 471 Adjusting transmission speed sensor............................................................................................................................. 479 Testing and adjusting brake oil pressure........................................................................................................................ 480 Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas........................................................... 483 Testing brake performance....................................................................................................................................... 487 Bleeding air from brake circuit................................................................................................................................. 489 Bleeding air from ASR circuit (if equipped)..................................................................................................................... 491 Testing wear of front brake disc................................................................................................................................ 492 Testing wear of rear brake disc................................................................................................................................. 493 Method of releasing parking brake in an emergency............................................................................................................... 494 Testing and adjusting front suspension cylinder................................................................................................................. 495 Testing and adjusting rear suspension cylinder.................................................................................................................. 499 Testing and adjusting front suspension cylinder (Automatic suspension specification)............................................................................ 503 Testing and adjusting hydraulic pressure in steering, hoist circuit............................................................................................. 504 Testing and adjusting oil pressure in dump EPC circuit.......................................................................................................... 507 Air bleeding from steering cylinder............................................................................................................................. 508 Procedure for raising dump body in emergency.................................................................................................................... 509 Adjusting body positioner sensor................................................................................................................................ 510 Handling of high voltage circuit of engine controller........................................................................................................... 512 Adjusting transmission controller............................................................................................................................... 512 Method for emergency escape at electrical system failure........................................................................................................ 513 Testing and adjusting, Part 3....................................................................................................................................... 519 Setting and adjusting of devices................................................................................................................................ 520 Testing and adjusting, Part 4....................................................................................................................................... 533 Special functions of machine monitor (EMMS)..................................................................................................................... 534 Testing and adjusting, Part 5....................................................................................................................................... 603 Opening ORBCOMM terminal........................................................................................................................................ 604 VHMS controller initial setting procedure....................................................................................................................... 606 Precautions for replacing VHMS controller....................................................................................................................... 631 Pm Clinic check sheet........................................................................................................................................... 637 Initial setting of payload meter................................................................................................................................ 641 Setting of payload meter built in VHMS.......................................................................................................................... 642 40 Troubleshooting...................................................................................................................................................... 651 Failure code table and fuse locations............................................................................................................................... 651 Failure codes table............................................................................................................................................. 652 Fuse locations.................................................................................................................................................. 668 General information on troubleshooting.............................................................................................................................. 675 Points to remember when troubleshooting......................................................................................................................... 676 Sequence of events in troubleshooting........................................................................................................................... 677 Check before troubleshooting.................................................................................................................................... 678 Classification and procedures for troubleshooting............................................................................................................... 679 Contents of troubleshooting table............................................................................................................................... 680 Connection table for connector pin numbers...................................................................................................................... 682 T- branch box and T- branch adapter table....................................................................................................................... 718 Troubleshooting by failure code, Part 1............................................................................................................................. 723 Failure code [1500L0] Dual engagement........................................................................................................................... 725 Failure code [15B0NX] Transmission oil filter: Clogging......................................................................................................... 726 Failure code [15F0KM] R β F shifting abuse 1: Mistake in operation.............................................................................................. 728 Failure code [15F0MB] R β F shifting abuse 2: Mistake in operation.............................................................................................. 728 Failure code [15F7KM] Forward clutch disk abuse: Mistake in operation or setting................................................................................ 729 Failure code [15G0MW] R clutch: Slipping........................................................................................................................ 730 Failure code [15G7KM] Reverse clutch disk abuse: Mistake in operation or setting................................................................................ 732 Failure code [15H0MW] Hi clutch: Slipping....................................................................................................................... 734 Failure code [15J0MW] Lo clutch: Slipping....................................................................................................................... 736 Failure code [15K0MW] 1st clutch: Slipping...................................................................................................................... 738 Failure code [15L0MW] 2nd clutch: Slipping...................................................................................................................... 740 Failure code [15M0MW] 3rd clutch: Slipping...................................................................................................................... 742 Failure code [15N0MW] 4th clutch: Slipping...................................................................................................................... 744 Failure code [15SBL1] R clutch solenoid: Fill signal is ON when command current is OFF.......................................................................... 746 Failure code [15SBMA] R clutch solenoid: Malfunction............................................................................................................ 748 Failure code [15SCL1] Hi clutch solenoid: Fill signal is ON when command current is OFF......................................................................... 750 Failure code [15SCMA] Hi clutch solenoid: Malfunction........................................................................................................... 754 Failure code [15SDL1] Lo clutch solenoid: Fill signal is ON when command current is OFF......................................................................... 756 Failure code [15SDMA] Lo clutch solenoid: Malfunction........................................................................................................... 760 Failure code [15SEL1] 1st clutch solenoid: Fill signal is ON when command current is OFF........................................................................ 762 Failure code [15SEMA] 1st clutch solenoid: Malfunction.......................................................................................................... 766 Troubleshooting by failure code, Part 2............................................................................................................................. 769 Failure code [15SFL1] 2nd clutch solenoid: Fill signal is ON when command current is OFF........................................................................ 771 Failure code [15SFMA] 2nd clutch solenoid: Malfunction.......................................................................................................... 774 Failure code [15SGL1] 3rd clutch solenoid: Fill signal is ON when command current is OFF........................................................................ 776 Failure code [15SGMA] 3rd clutch solenoid: Malfunction.......................................................................................................... 780 Failure code [15SHL1] 4th clutch solenoid: Fill signal is ON when command current is OFF........................................................................ 782 Failure code [15SHMA] 4th clutch solenoid: Malfunction.......................................................................................................... 786 Failure code [15SJMA] Lockup clutch solenoid: Malfunction....................................................................................................... 788 Failure code [2F00KM] Parking brake: Mistake in operation or setting............................................................................................ 789 Failure code [2G42ZG] Accumulator: Oil pressure reduction (Front)............................................................................................... 792 Failure code [2G43ZG] Accumulator: Oil pressure reduction (Rear)................................................................................................ 792 Failure code [989A00] Engine over run prevention command signal: Operating...................................................................................... 793 Failure code [989D00] Rear section tipping over alarm: Alarm is activated....................................................................................... 793 Failure code [A570NX] Engine oil filter: Clogging............................................................................................................... 794 Failure code [AA10NX] Air cleaner element: Clogging............................................................................................................. 796 Failure code [AB00L4] Alternator: Failure on battery charge circuit (R terminal signal is present and engine is stopped)........................................ 798 Failure code [AB00MA] Alternator: Malfunction................................................................................................................... 800 Failure code [AB00MB] Alternator: Failure on battery charge circuit (Absence of R terminal signal and detection error).......................................... 802 Failure code [B@BAZG] Abnormal lowering of engine oil pressure: Lowering of oil pressure........................................................................ 804 Failure code [B@BAZK] Engine oil: Level too low................................................................................................................. 806 Failure code [B@BCNS] Engine: Overheat.......................................................................................................................... 808 Failure code [B@BCZK] Lowering of radiator coolant: Lowering of level........................................................................................... 810 Failure code [B@BFZK] Lowering of fuel level.................................................................................................................... 812 Failure code [B@C6NS] Brake cooling oil: Overheating (Front).................................................................................................... 814 Failure code [B@C7NS] Brake cooling oil: Overheating (Rear)..................................................................................................... 815 Failure code [B@CENS] Overheating of torque converter oil....................................................................................................... 816 Failure code [B@GAZK] Battery electrolyte level: Lowering of level.............................................................................................. 817 Failure code [B@JANS] Steering oil: Overheat.................................................................................................................... 818 Troubleshooting by failure code, Part 3............................................................................................................................. 821 Failure code [CA111] Engine controller (Left bank): Internal abnormality........................................................................................ 824 Failure code [CB111] Engine controller (Right bank): Internal abnormality....................................................................................... 826 Failure code [CA115] Abnormal engine Ne and Bkup speed sensors (Left bank): Abnormal speed sensor signal........................................................ 828 Failure code [CB115] Abnormal engine Ne and Bkup speed sensors (Right bank): Abnormal speed sensor signal....................................................... 829 Failure code [CA122] Charge pressure sensor too high (At left bank only): Excessively high voltage detected..................................................... 830 Failure code [CA123] Charge pressure sensor too low (At left bank only): Excessively low voltage detected....................................................... 832 Failure code [CA131] Throttle sensor high error (At left bank only)............................................................................................. 834 Failure code [CA132] Throttle sensor low error (At left bank only).............................................................................................. 837 Failure code [CA135] Oil pressure sensor too high (At left bank only): Excessively high voltage detected........................................................ 838 Failure code [CA141] Oil pressure sensor too low (At left bank only): Excessively low voltage detected.......................................................... 840 Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected..................................................................... 842 Failure code [CA145] Coolant temperature sensor too low (At left bank only): Excessively low voltage detected................................................... 844 Failure code [CA153] Charge temperature sensor too high (At left bank only): Excessively high voltage detected.................................................. 846 Failure code [CA154] Charge temperature sensor too low (At left bank only): Excessively low voltage detected.................................................... 848 Failure code [CA187] Sensor power supply (2) abnormally low level (Left bank): Low voltage detection............................................................ 850 Failure code [CB187] Sensor power supply (2) abnormally low level (Right bank): Low voltage detection........................................................... 850 Failure code [CA212] Engine oil temperature sensor abnormally high level (At left bank only): High voltage detection............................................ 852 Failure code [CA213] Engine oil temperature sensor abnormally low level (At left bank only): Low voltage detection.............................................. 854 Failure code [CA221] Atmospheric pressure sensor too high (At left bank only): Excessively high voltage detected................................................ 856 Failure code [CA222] Atmospheric pressure sensor too low (At left bank only): Excessively low voltage detected.................................................. 858 Failure code [CA227] Sensor power source (2) too high (Left bank): Excessively high voltage detected............................................................ 860 Failure code [CB227] Sensor power supply (2) abnormally high level (Right bank): High voltage detection......................................................... 862 Failure code [CA234] Engine over speed (At left bank only): Excessively high speed.............................................................................. 864 Failure code [CA238] Abnormal power source for Ne speed sensor (At left bank only): Excessively low voltage detected............................................ 866 Failure code [CB238] Abnormal power source for Ne speed sensor (At right bank only): Excessively low voltage detected........................................... 868 Failure code [CA263] Fuel temperature sensor too high (Left bank): Excessively high voltage detected............................................................ 870 Failure code [CB263] Fuel temperature sensor too high (Right bank): Excessively high voltage detected........................................................... 872 Failure code [CA265] Fuel temperature sensor abnormally low level (Left bank): Low voltage detection............................................................ 874 Failure code [CB265] Fuel temperature sensor abnormally low level (Right bank): Low voltage detection........................................................... 874 Failure code [CA271] PCV1 short circuit (Left bank): Short circuit.............................................................................................. 875 Failure code [CB271] PCV1 short circuit (Right bank): Short circuit............................................................................................. 876 Failure code [CA272] PCV1 disconnection (Left bank): Disconnection.............................................................................................. 877 Failure code [CB272] PCV1 disconnection (Right bank): Disconnection............................................................................................. 878 Failure code [CA273] PCV2 short circuit (Left bank): Short circuit.............................................................................................. 879 Failure code [CB273] PCV2 short circuit (Right bank): Short circuit............................................................................................. 880 Failure code [CA274] PCV2 disconnection (Left bank): Disconnection.............................................................................................. 881 Failure code [CB274] PCV2 disconnection (Right bank): Disconnection............................................................................................. 882 Troubleshooting by failure code, Part 4............................................................................................................................. 885 Failure code [CA322] Injector No. 1 (L/B No.1) system disconnection or short circuit (Left bank): Disconnection, short circuit.................................. 888 Failure code [CA323] Injector No. 5 (L/B No.5) system disconnection or short circuit (Left bank): Disconnection, short circuit.................................. 890 Failure code [CA324] Injector No. 3 (L/B No.3) system disconnection or short circuit (Left bank): Disconnection, short circuit.................................. 892 Failure code [CA325] Injector No. 6 (L/B No.6) system disconnection or short circuit (Left bank): Disconnection, short circuit.................................. 894 Failure code [CA331] Injector No. 2 (L/B No.2) system disconnection or short circuit (Left bank): Disconnection, short circuit.................................. 896 Failure code [CA332] Injector No. 4 (L/B No.4) system disconnection or short circuit (Left bank): Disconnection, short circuit.................................. 898 Failure code [CA342] Engine controller data mismatch (Left bank): Mismatch...................................................................................... 900 Failure code [CB342] Engine controller data mismatch (Right bank): Mismatch..................................................................................... 900 Failure code [CA351] Abnormal injector drive circuit (Left bank): Abnormal circuit.............................................................................. 902 Failure code [CB351] Injector drive circuit abnormality (Right bank): Circuit abnormality....................................................................... 904 Failure code [CA352] Sensor power supply (1) abnormally low level (Left bank): Low voltage detection............................................................ 906 Failure code [CB352] Sensor power supply (1) abnormally low level (Right bank): Low voltage detection........................................................... 906 Failure code [CA386] Sensor power supply (1) abnormally high level (Left bank): High voltage detection.......................................................... 908 Failure code [CB386] Sensor power supply (1) abnormally high level (Right bank): High voltage detection......................................................... 910 Failure code [CA431] Trouble in idle validation switch.......................................................................................................... 912 Failure code [CA432] Idle validation action error............................................................................................................... 916 Failure code [CA441] Power supply voltage abnormally low level (Left bank): Low voltage detection............................................................... 917 Failure code [CB441] Power supply voltage abnormally low level (Right bank): Low voltage detection.............................................................. 917 Failure code [CA442] Power supply voltage abnormally high level (Left bank): High voltage detection............................................................. 918 Failure code [CB442] Power supply voltage abnormally high level (Right bank): High voltage detection............................................................ 918 Failure code [CA449] Common rail abnormally high pressure (2) (Left bank): Abnormally high pressure occurrence.................................................. 919 Failure code [CB449] Common rail abnormally high pressure (2) (Right bank): Abnormally high pressure occurrence................................................. 919 Failure code [CA451] Common rail pressure sensor too high (Left bank): Excessively high voltage detected........................................................ 920 Failure code [CB451] Common rail pressure sensor abnormally high level (Right bank): High voltage detection..................................................... 922 Failure code [CA452] Common rail pressure sensor abnormally low level (Left bank): Abnormally low voltage detection............................................. 924 Failure code [CB452] Common rail pressure sensor abnormally low level (Right bank): Abnormally low voltage detection............................................ 924 Failure code [CA553] Common rail pressure too high (1) (Left bank): Excessively high pressure detected.......................................................... 925 Failure code [CB553] Common rail pressure too high (1) (Right bank): Excessively high pressure detected......................................................... 926 Failure code [CA554] In-range error in common rail pressure sensor (Left bank): In-range error.................................................................. 927 Failure code [CB554] In-range error in common rail pressure sensor (Right bank): In-range error................................................................. 927 Failure code [CA559] Loss of pressure feed from supply pump (1) (Left bank): Loss of pressure feed detected..................................................... 928 Failure code [CB559] Loss of pressure feed from supply pump (1) (Right bank): Loss of pressure feed detected.................................................... 932 Failure code [CA689] Abnormal engine Ne speed sensor (Left bank): Abnormal signal............................................................................... 936 Failure code [CB689] Abnormal engine Ne speed sensor (Right bank): Abnormal signal.............................................................................. 938 Failure code [CA691] Intake air temperature sensor abnormally high level (At left bank only): High voltage detection............................................ 940 Failure code [CA692] Intake air temperature sensor abnormally low level (At left bank only): Low voltage detection.............................................. 942 Failure code [CA731] Abnormal engine Bkup speed sensor phase (Left bank): Abnormal phase........................................................................ 943 Failure code [CB731] Abnormal engine Bkup speed sensor phase (Right bank): Abnormal phase....................................................................... 943 Troubleshooting by failure code, Part 5............................................................................................................................. 945 Failure code [CA757] Loss of all engine controller data (Left bank): Loss of all data........................................................................... 947 Failure code [CB757] Loss of all engine controller data (Right bank): Loss of all data.......................................................................... 947 Failure code [CA778] Abnormal engine Bkup speed sensor (Left bank): Abnormal Bkup signal........................................................................ 948 Failure code [CB778] Engine Bkup speed sensor abnormality (Right bank): Bkup signal error....................................................................... 950 Failure code [CA781] Inter-multicontroller communication error (Left bank): Communication error................................................................. 952 Failure code [CB781] Inter-multicontroller communication error (Right bank): Communication error................................................................ 954 Failure code [CA1257] Multicontroller distinction wiring harness key error (Left bank): Distinction error....................................................... 955 Failure code [CB1257] Multicontroller distinction wiring harness key error (Right bank): Distinction error...................................................... 956 Failure code [CB1548] Injector #7 (R/B #1) system disconnection/short circuit (Right bank): Disconnection/Short circuit......................................... 958 Failure code [CB1549] Injector #8 (R/B #2) system disconnection/short circuit (Right bank): Disconnection/Short circuit......................................... 960 Failure code [CB1551] Injector #10 (R/B #4) system disconnection/short circuit (Right bank): Disconnection/Short circuit........................................ 962 Failure code [CB1552] Injector #11 (R/B #5) system disconnection/short circuit (Right bank): Disconnection/Short circuit........................................ 964 Failure code [CB1553] Injector #12 (R/B #6) system disconnection/short circuit (Right bank): Disconnection/Short circuit........................................ 966 Failure code [CB1622] Injector #9 (R/B #3) system disconnection/short circuit (Right bank): Disconnection/Short circuit......................................... 968 Failure code [CA1633] KOMNET abnormality (Left bank): Communication error....................................................................................... 970 Failure code [CA2185] Throttle sensor supply voltage high error................................................................................................. 972 Failure code [CA2186] Throttle sensor power supply low error.................................................................................................... 974 Failure code [CA2249] Loss of pressure feed from supply pump (2) (Left bank): Loss of pressure feed detected.................................................... 975 Failure code [CB2249] Loss of pressure feed from supply pump (2) (Right bank): Loss of pressure feed detected................................................... 975 Failure code [CA2555] Intake heater relay voltage low error (Left bank)......................................................................................... 976 Failure code [CA2556] Intake heater relay voltage high error (Left bank)........................................................................................ 978 Troubleshooting by failure code, Part 6............................................................................................................................. 981 Failure code [D180KA] Preheating relay output system: Disconnection............................................................................................. 983 Failure code [D180KB] Preheating relay output system: Grounding fault........................................................................................... 984 Failure code [D180KY] Preheating relay output system: Hot short circuit......................................................................................... 986 Failure code [D19HKB] Stop lamp relay output system: Short circuit.............................................................................................. 988 Failure code [D1EFKA] Pre-lubrication start relay output system: Disconnection.................................................................................. 990 Failure code [D1EFKB] Pre-lubrication start relay output system: Grounding fault................................................................................ 992 Failure code [D1EFKY] Pre-lubrication start relay output system: Hot short circuit.............................................................................. 994 Failure code [DAF9KM] Wrong connection of connector............................................................................................................. 996 Failure code [DAFRKR] CAN communication error (Machine monitor): Communication error............................................................................ 997 Failure code [DAQ0KK] Transmission controller direct power supply: Lowering of source voltage...................................................................1000 Failure code [DAQ0KT] Transmission controller nonvolatile memory: Abnormality in controller.....................................................................1002 Failure code [DAQ2KK] Transmission controller solenoid power source: Power source voltage too low...............................................................1003 Failure code [DAQ9KQ] Transmission controller: Disagreement of model selection..................................................................................1004 Failure code [DAQRKR] Abnormality in CAN communication (Transmission)...........................................................................................1004 Failure code [DAQRMA] Transmission controller option setting: Malfunction.......................................................................................1005 Failure code [DB10KT] Retarder controller nonvolatile memory: Abnormality in controller.........................................................................1005 Failure code [DB12KK] Retarder controller solenoid power source: Power source system trouble....................................................................1006 Failure code [DB13KK] Retarder controller battery direct power source: Power source voltage too low.............................................................1008 Failure code [DB19KQ] Disagreement of model selection (Retarder controller).....................................................................................1010 Failure code [DB1RKR] CAN communication (retarder controller): Communication disabled...........................................................................1011 Failure code [DB1RMA] Disagreement of option setting (Retarder controller)......................................................................................1014 Failure code [DB2RKR] CAN communication (engine controller): Communication disabled.............................................................................1015 Failure code [dB2RKR] CAN communication (engine controller): Communication disabled.............................................................................1018 Failure code [DBB0KK] (or VHMS_LED display: "n9" β "01") VHMS controller: Low source voltage (input)............................................................1022 Failure code [DBB0KQ] (or VHMS_LED display: "nF" β "11") (VHMS controller: Disagreement of model selection signals).............................................1024 Failure code [DBB3KK] (or VHMS_LED display: "n9" β "05") VHMS controller battery power supply: Low source voltage (input).......................................1026 Failure code [DBB5KP] (or VHMS_LED display: "n9" β "04") (VHMS controller 5 V power supply output: Low output voltage)..........................................1028 Failure code [DBB6KP] (or VHMS_LED display: "n9" β "02") (VHMS controller 24 V power supply output: Low output voltage).........................................1030 Failure code [DBB7KP] (or VHMS_LED display: "n9" β "03") (VHMS controller 12 V power supply output: Low output voltage).........................................1032 Failure code [DBBQKR] (or VHMS_LED display: "n8" β "02") VHMS controller CAN communication: Defective communication (Abnormality in target component system)....1034 Failure code [DBBRKR] Abnormality in CAN communication (VHMS)...................................................................................................1036 Failure code [DBC2KK] ABS controller solenoid power source: Power source system trouble.........................................................................1038 Failure code [DBC3KK] ABS controller battery direct power source: Power source voltage too low..................................................................1040 Failure code [DBC9KQ] Disagreement of model selection (ABS controller)..........................................................................................1042 Failure code [DBCRKR] Abnormality in CAN communication (ABS)....................................................................................................1042 Failure code [DBCRMA] Disagreement of option setting (ABS controller)...........................................................................................1043 Failure code [DBG2KK] Solenoid power supply: Low voltage........................................................................................................1044 Failure code [DBG3KK] Battery direct power supply: Low voltage..................................................................................................1046 Failure code [DBG9KQ] Model selection signal: Abnormal..........................................................................................................1048 Failure code [DDD7KX] Trouble in travel speed setting switch system: Out of input signal range..................................................................1050 Failure code [DDD8KA] ARSC system switch system: Disconnection..................................................................................................1052 Failure code [DDD8KB] ARSC system switch system: Short circuit..................................................................................................1054 Failure code [DDD9KA] ABS system switch system: Disconnection...................................................................................................1056 Failure code [DDD9KB] ABS system switch system: Short circuit...................................................................................................1058 Failure code [DDDAKA] ASR system switch: Disconnection..........................................................................................................1060 Failure code [DDDAKB] ASR system switch: Short circuit..........................................................................................................1062 Failure code [DDE2KB] Engine oil pressure switch error: Grounding fault.........................................................................................1064 Failure code [DDE2L6] Engine oil pressure switch error: Disconnection or hot short circuit......................................................................1066 Failure code [DDP6L4] Service brake pressure switch trouble (Rear)..............................................................................................1068 Failure code [DDTHKA] Hi clutch fill switch: Disconnection......................................................................................................1070 Failure code [DDTJKA] Lo clutch fill switch: Disconnection......................................................................................................1072 Failure code [DDTKKA] 1st clutch fill switch: Disconnection.....................................................................................................1074 Failure code [DDTLKA] 2nd clutch fill switch: Disconnection.....................................................................................................1076 Failure code [DDTMKA] 3rd clutch fill switch: Disconnection.....................................................................................................1078 Failure code [DDTNKA] R clutch fill switch: Disconnection.......................................................................................................1080 Failure code [DDTPKA] 4th clutch fill switch: Disconnection.....................................................................................................1082 Failure code [DF10KA] Gear shift lever: Disconnection...........................................................................................................1084 Failure code [DF10KB] Gear shift lever: Short circuit...........................................................................................................1087 Failure code [DGE5KX] (or VHMS_LED display: "n4" β "01") (Atmospheric temperature sensor: Out of input signal range)............................................1090 Failure code [DGF1KX] Transmission oil temperature sensor: Out of input signal range............................................................................1092 Failure code [DGR2KB] Trouble in retarder oil temperature sensor (rear wheel) system (Disconnection and short circuit)..........................................1094 Failure code [DGR2KZ] Trouble in retarder oil temperature sensor (rear wheel) system (Ground fault).............................................................1096 Failure code [DGR4KB] Trouble in retarder oil temperature sensor (front wheel) system (Disconnection and short circuit).........................................1098 Failure code [DGR4KZ] Trouble in retarder oil temperature sensor (front wheel) system (Ground fault)............................................................1100 Failure code [DGR6KX] Steering oil temperature sensor: Input signal out of range................................................................................1102 Failure code [DGT1KX] Torque converter oil temperature sensor: Out of input signal range........................................................................1104 Troubleshooting by failure code, Part 7.............................................................................................................................1107 Failure code [DGT5KA] (or VHMS_LED display: "n3" β "12") Left bank exhaust temperature sensor system (Front): Disconnection.....................................1109 Failure code [dGT5KA] (or VHMS_LED display: "n3" β "22") Left bank exhaust temperature sensor system (Rear): Disconnection......................................1112 Failure code [DGT5KB] (or VHMS_LED display: "n3" β "11") Left bank exhaust temperature sensor system (Front): Short circuit.....................................1115 Failure code [dGT5KB] (or VHMS_LED display: "n3" β "21") Left bank exhaust temperature sensor system (Rear): Short circuit......................................1118 Failure code [DGT6KA] (or VHMS_LED display: "n3" β "24") Right bank exhaust temperature sensor system (Front): Disconnection....................................1121 Failure code [dGT6KA] (or VHMS_LED display: "n3" β "26") Right bank exhaust temperature sensor system (Rear): Disconnection.....................................1124 Failure code [DGT6KB] (or VHMS_LED display: "n3" β "23") Right bank exhaust temperature sensor system (Front): Short circuit....................................1127 Failure code [dGT6KB] (or VHMS_LED display: "n3" β "25") Right bank exhaust temperature sensor system (Rear): Short circuit.....................................1130 Failure code [DHE5KB] (or VHMS_LED display: "n3" β "32") (Blow-by pressure sensor: Short circuit)...............................................................1134 Failure code [DHE5KY] (or VHMS_LED display: "n3" β "31") (Blow-by pressure sensor: Short circuit with power supply line)........................................1136 Failure code [DHP4KY] (or VHMS_LED display: "n5" β "44") Suspension pressure sensor system: Short circuit (Right front).........................................1138 Failure code [DHP4KZ] (or VHMS_LED display: "n5" β "43") Suspension pressure sensor system: Disconnection or ground fault (Right front).........................1140 Failure code [DHP5KY] (or VHMS_LED display: "n5" β "54") Suspension pressure sensor system: Short circuit (Left front)..........................................1142 Failure code [DHP5KZ] (or VHMS_LED display: "n5" β "53") Suspension pressure sensor system: Disconnection or ground fault (Left front)..........................1144 Failure code [DHP6KA] Suspension pressure sensor system: Disconnection (Right rear).............................................................................1146 Failure code [DHP6KX] Failure in suspension pressure sensor system trouble: Out of input signal range (Right rear)..............................................1148 Failure code [DHP6KY] (or VHMS_LED display: "n5" β "64") Suspension pressure sensor system: Short circuit (Right rear)..........................................1150 Failure code [DHP6KZ] (or VHMS_LED display: "n5" β "63") Suspension pressure sensor system: Disconnection or ground fault (Right rear)..........................1152 Failure code [DHP7KA] Suspension pressure sensor system: Disconnection (Left rear)..............................................................................1154 Failure code [DHP7KX] Failure in suspension pressure sensor system: Out of input signal range (Left rear).......................................................1156 Failure code [DHP7KY] (or VHMS_LED display: "n5" β "74") Suspension pressure sensor system: Short circuit (Left rear)...........................................1158 Failure code [DHP7KZ] (or VHMS_LED display: "n5" β "73") Suspension pressure sensor system: Disconnection or ground fault (Left rear)...........................1160 Failure code [DHT5KX] Torque converter oil pressure sensor: Out of input signal range...........................................................................1162 Failure code [DHT5L6] Torque converter oil pressure sensor: Disagreement of run and stop condition with signal..................................................1164 Failure code [DHU2KX] Front accumulator oil pressure sensor: Out of input signal range..........................................................................1166 Failure code [DHU3KX] Rear accumulator oil pressure sensor: Out of input signal range...........................................................................1168 Failure code [DHU6KX] Trouble in ABS control valve pressure sensor (Front right)................................................................................1170 Failure code [DHU7KX] Trouble in ABS control valve pressure sensor (Front left).................................................................................1172 Failure code [DHU8KX] Trouble in ABS control valve pressure sensor (Rear right).................................................................................1174 Failure code [DHU9KX] Trouble in ABS control valve pressure sensor (Rear left)..................................................................................1176 Failure code [DJF1KA] Fuel level sensor: Disconnection..........................................................................................................1178 Failure code [DK30KX] Steering angle potentiometer: Trouble (Disconnection).....................................................................................1179 Failure code [DK51L5] Trouble in retarder lever potentiometer and RVS...........................................................................................1180 Failure code [DK52KX] Failure in hoist lever potentiometer 1: Out of input signal range.........................................................................1184 Failure code [DK53L8] Failure in hoist lever potentiometer 2: Disagreement of analog signal.....................................................................1186 Failure code [DK54KX] Body positioner sensor: Out of input signal range.........................................................................................1188 Failure code [DKD0L6] Failure in steering angle speed sensor....................................................................................................1190 Failure code [DKH0KX] Pitch angle sensor: Out of input signal range.............................................................................................1192 Failure code [DKH1KX] (or VHMS_LED display: "n4" β "33") Pitch angle sensor: Abnormality........................................................................1194 Failure code [DLF1KA] Transmission input shaft speed sensor: Disconnection......................................................................................1196 Failure code [DLF1LC] Transmission input shaft speed sensor: Disagreement of revolution speed signal............................................................1198 Failure code [DLF2KA] Transmission intermediate shaft speed sensor: Disconnection...............................................................................1200 Failure code [DLF2LC] Transmission intermediate shaft speed sensor: Disagreement of revolution speed signal.....................................................1202 Troubleshooting by failure code, Part 8.............................................................................................................................1205 Failure code [DLF6KA] Disconnection in wheel speed sensor (Front right).........................................................................................1208 Failure code [DLF6L3] Trouble in wheel speed sensor (Front right)...............................................................................................1210 Failure code [DLF7KA] Disconnection in wheel speed sensor (Front left)..........................................................................................1212 Failure code [DLF7L3] Trouble in wheel speed sensor (Front left)................................................................................................1214 Failure code [DLF8KA] Wheel speed sensor: Disconnection (Rear right)............................................................................................1216 Failure code [DLF8L3] Wheel speed sensor: Disconnection (Rear right)............................................................................................1218 Failure code [DLF8LC] Wheel speed sensor: Trouble (Rear right)..................................................................................................1220 Failure code [DLF8MA] Wheel speed sensor: Disconnection (Rear right)............................................................................................1220 Failure code [DLF9KA] Wheel speed sensor: Disconnection (Rear left).............................................................................................1222 Failure code [DLF9L3] Wheel speed sensor: Trouble (Rear left)...................................................................................................1224 Failure code [DLF9LC] Wheel speed sensor: Trouble (Rear left)...................................................................................................1226 Failure code [DLF9MA] Wheel speed sensor: Disconnection (Rear left).............................................................................................1226 Failure code [DLT3KA] Transmission output shaft speed sensor: Disconnection.....................................................................................1228 Failure code [DLT3LC] Transmission output shaft speed sensor: Disagreement of revolution speed signal...........................................................1230 Failure code [DLT4KA] Transmission output shaft speed sensor: Disconnection.....................................................................................1232 Failure code [DLT4MA] Transmission output shaft speed sensor: Disconnection.....................................................................................1234 Failure code [DUM7KY] Pre-lubrication operation lamp output abnormality: Hot short circuit......................................................................1236 Failure code [DUM7KZ] Pre-lubrication operation lamp output abnormality: Disconnection or grounding fault.......................................................1238 Failure code [DV00KB] Buzzer output: Short circuit..............................................................................................................1240 Failure code [DW2AKA] Main pressure variable valve output: Disconnection........................................................................................1242 Failure code [DW2AKB] Main pressure variable valve output circuit: Ground fault.................................................................................1244 Failure code [DW2AKY] Main pressure variable valve output circuit: Hot short....................................................................................1246 Failure code [DW2AL1] Main pressure variable valve: Defective reset.............................................................................................1248 Failure code [DW2ALH] Main pressure variable valve: Malfunction.................................................................................................1250 Failure code [DW2BKA] Main oil level selector valve output: Disconnection.......................................................................................1251 Failure code [DW2BKB] Main oil level selector valve output circuit: Ground fault................................................................................1252 Failure code [DW2BKY] Main oil level selector valve output circuit: Hot short...................................................................................1254 Failure code [DW2BL1] Main oil level selector valve: Defective reset............................................................................................1256 Failure code [DW2BLH] Main oil level selector valve: Malfunction................................................................................................1258 Failure code [DW2CKA] Transmission lubrication variable valve output: Disconnection.............................................................................1259 Failure code [DW2CKB] Transmission lubrication variable valve output circuit: Ground fault......................................................................1260 Failure code [DW2CKY] Transmission lubrication variable valve output circuit: Hot short.........................................................................1262 Failure code [DW2CL1] Transmission lubrication variable valve: Defective reset..................................................................................1264 Failure code [DW2CLH] Transmission lubrication variable valve: Malfunction......................................................................................1266 Failure code [DW35KZ] Failure in output system of auto suspension solenoid 1: Disconnection or short circuit....................................................1268 Failure code [DW36KZ] Failure in output system of auto suspension solenoid 2: Disconnection or short circuit....................................................1270 Failure code [DW71KZ] Exhaust brake output system trouble (Disconection/Ground fault/Hot short).................................................................1272 Failure code [DW72KZ] Kick-out solenoid output system trouble: Disconnection or short circuit...................................................................1274 Failure code [DW73KZ] Failure in hoist select valve output system: Disconnection or short circuit...............................................................1276 Failure code [DW78KZ] Brake cooling valve (BCV) (rear wheel) output system trouble: Disconnection or short circuit..............................................1278 Failure code [DWNBK4] ASR shut-off valve: Trouble (Valve keeps operating).......................................................................................1280 Failure code [DWNBKA] ASR shut-off valve output circuit: Disconnection..........................................................................................1282 Failure code [DWNBKB] ASR shut-off valve output circuit: Ground fault...........................................................................................1284 Failure code [DWNBKY] ASR shut-off valve output circuit: Short circuit..........................................................................................1286 Failure code [DWNBMA] ASR shut-off valve: Trouble (Valve does not operate)......................................................................................1286 Failure code [DWNDKZ] Trouble in ABS cut-off valve (Front) system...............................................................................................1288 Failure code [DWNDMA] Defective ABS cut-off valve (Front).......................................................................................................1290 Failure code [DWNEKZ] Trouble in ABS cut-off valve (Rear) system................................................................................................1292 Failure code [DWNEMA] Defective ABS cut-off valve (Rear)........................................................................................................1294 Troubleshooting by failure code, Part 9.............................................................................................................................1297 Failure code [DX11K4] Rear brake proportional pressure reducing solenoid valve: Out of control..................................................................1300 Failure code [DX11KA] Rear brake proportional pressure reducing solenoid valve output circuit: Disconnection....................................................1302 Failure code [DX11KB] Rear brake proportional pressure reducing solenoid valve: Short circuit...................................................................1303 Failure code [DX11KY] Rear brake proportional pressure reducing solenoid valve: Short circuit to power source line..............................................1304 Failure code [DX11MA] Rear brake proportional pressure reducing solenoid valve: Malfunction.....................................................................1306 Failure code [DX12K4] Front brake proportional pressure reducing solenoid valve: Out of control.................................................................1308 Failure code [DX12KA] Front brake proportional pressure reducing solenoid valve output circuit: Disconnection...................................................1310 Failure code [DX12KB] Front brake proportional pressure reducing solenoid valve: Short circuit..................................................................1311 Failure code [DX12KY] Front brake proportional pressure reducing solenoid valve: Short circuit to power source line.............................................1312 Failure code [DX12MA] Front brake proportional pressure reducing solenoid valve: Malfunction....................................................................1314 Failure code [DX13KA] Output circuit of hoist EPC valve: Disconnection..........................................................................................1316 Failure code [DX13KB] Output circuit of hoist EPC valve: Short circuit..........................................................................................1318 Failure code [DX13KY] Output circuit of hoist EPC valve: Short circuit with power source line...................................................................1320 Failure code [DX17K4] ASR proportional pressure reducing solenoid valve (right): Trouble (Valve keeps operating)................................................1322 Failure code [DX17KA] ASR proportional pressure reducing solenoid valve (right) output circuit: Disconnection...................................................1324 Failure code [DX17KB] ASR proportional pressure reducing solenoid valve (right) output circuit: Ground fault....................................................1326 Failure code [DX17KY] ASR proportional pressure reducing solenoid valve (right) output circuit: Short circuit...................................................1328 Failure code [DX17MA] ASR proportional pressure reducing solenoid valve (right): Trouble (Valve does not operate)...............................................1328 Failure code [DX18K4] ASR proportional pressure reducing solenoid valve (left): Trouble (Valve keeps operating).................................................1330 Failure code [DX18KA] ASR proportional pressure reducing solenoid valve (left) output circuit: Disconnection....................................................1332 Failure code [DX18KB] ASR proportional pressure reducing solenoid valve (left) output circuit: Ground fault.....................................................1334 Failure code [DX18KY] ASR proportional pressure reducing solenoid valve (left) output circuit: Short circuit....................................................1336 Failure code [DX18MA] ASR proportional pressure reducing solenoid valve (left): Trouble (Valve does not operate)................................................1336 Failure code [DX21KA] Disconnection in ABS control valve output circuit (Front right)...........................................................................1337 Failure code [DX21KB] Ground fault in ABS control valve output circuit (Front right)............................................................................1338 Failure code [DX21KY] Hot short in ABS control valve output circuit (Front right)...............................................................................1339 Failure code [DX21MA] Defective ABS control valve (Front right).................................................................................................1340 Failure code [DX22KA] Disconnection in ABS control valve output circuit (Front left)............................................................................1341 Failure code [DX22KB] Ground fault in ABS control valve output circuit (Front left).............................................................................1342 Failure code [DX22KY] Hot short in ABS control valve output circuit (Front left)................................................................................1343 Failure code [DX22MA] Defective ABS control valve (Front left)..................................................................................................1344 Failure code [DX23KA] Disconnection in ABS control valve output circuit (Rear right)............................................................................1345 Failure code [DX23KB] Ground fault in ABS control valve output circuit (Rear right).............................................................................1346 Failure code [DX23KY] Hot short in ABS control valve output circuit (Rear right)................................................................................1347 Failure code [DX23MA] Defective ABS control valve (Rear right)..................................................................................................1348 Failure code [DX24KA] Disconnection in ABS control valve output circuit (Rear left).............................................................................1349 Failure code [DX24KB] Ground fault in ABS control valve output circuit (Rear left)..............................................................................1350 Failure code [DX24KY] Hot short in ABS control valve output circuit (Rear left).................................................................................1351 Failure code [DX24MA] Defective ABS control valve (Rear left)...................................................................................................1352 Failure code [DX25MA] Defective ABS front wheel system control valve............................................................................................1353 Failure code [DX26MA] Defective ABS rear wheel system control valve.............................................................................................1353 Troubleshooting by failure code, Part 10............................................................................................................................1355 Failure code [DXH1KA] Lockup clutch solenoid output circuit: Disconnection......................................................................................1357 Failure code [DXH1KB] Lock-up clutch solenoid output circuit: Short circuit.....................................................................................1358 Failure code [DXH1KY] Lockup clutch solenoid output circuit: Short circuit to power source line.................................................................1359 Failure code [DXH2KA] Hi clutch solenoid output circuit: Disconnection..........................................................................................1360 Failure code [DXH2KB] Hi clutch solenoid output circuit: Short circuit..........................................................................................1362 Failure code [DXH2KY] Hi clutch solenoid output circuit: Short circuit to power source line.....................................................................1364 Failure code [DXH3KA] Lo clutch solenoid output circuit: Disconnection..........................................................................................1368 Failure code [DXH3KB] Lo clutch solenoid output circuit: Short circuit..........................................................................................1370 Failure code [DXH3KY] Lo clutch solenoid output circuit: Short circuit in power source line.....................................................................1372 Failure code [DXH4KA] 1st clutch solenoid output circuit: Disconnection.........................................................................................1376 Failure code [DXH4KB] 1st clutch solenoid output circuit: Short circuit.........................................................................................1378 Failure code [DXH4KY] 1st clutch solenoid output circuit: Short circuit to power source line....................................................................1380 Failure code [DXH5KA] 2nd clutch solenoid output circuit: Disconnection.........................................................................................1384 Failure code [DXH5KB] 2nd clutch solenoid output circuit: Short circuit.........................................................................................1386 Failure code [DXH5KY] 2nd clutch solenoid output circuit: Short circuit in power source line....................................................................1388 Failure code [DXH6KA] 3rd clutch solenoid output circuit: Disconnection.........................................................................................1392 Failure code [DXH6KB] 3rd clutch solenoid output circuit: Short circuit.........................................................................................1394 Failure code [DXH6KY] 3rd clutch solenoid output circuit: Short circuit to power source line....................................................................1396 Failure code [DXH7KA] R clutch solenoid output circuit: Disconnection...........................................................................................1400 Failure code [DXH7KB] R clutch solenoid output circuit: Short circuit...........................................................................................1402 Failure code [DXH7KY] R clutch solenoid output circuit: Short circuit to power source line......................................................................1404 Failure code [DXHHKA] 4th clutch solenoid output circuit: Disconnection.........................................................................................1406 Failure code [DXHHKB] 4th clutch solenoid output circuit: Short circuit.........................................................................................1408 Failure code [DXHHKY] 4th clutch solenoid output circuit: Short circuit to power source line....................................................................1410 Failure code [F@BBZL] (or VHMS_LED display: "n3" β "38") (Blow-by pressure: High error..........................................................................1414 Failure code [F@BYNS] (or VHMS_LED display "n3" β "61") Left front exhaust temperature sensor (1): Exhaust temperature abnormal rise............................1416 Failure code [f@BYNS] (or VHMS_LED display "n3" β "71") Left rear exhaust temperature sensor (1): Exhaust temperature abnormal rise.............................1418 Failure code [F@BZNS] (or VHMS_LED display "n3" β "81") Right front exhaust temperature sensor (1): Exhaust temperature abnormal rise...........................1420 Failure code [f@BZNS] (or VHMS_LED display "n3" β "91") Right rear exhaust temperature sensor (1): Exhaust temperature abnormal rise............................1422 Failure code [F@BYNR] (or VHMS_LED display "n3" β "62") Left front exhaust temperature sensor (2): Exhaust temperature abnormal rise............................1424 Failure code [f@BYNR] (or VHMS_LED display "n3" β "72") Left rear exhaust temperature sensor (2): Exhaust temperature abnormal rise.............................1426 Failure code [F@BZNR] (or VHMS_LED display "n3" β "82") Right front exhaust temperature sensor (2): Exhaust temperature abnormal rise...........................1428 Failure code [f@BZNR] (or VHMS_LED display "n3" β "92") Right rear exhaust temperature sensor (2): Exhaust temperature abnormal rise............................1430 Troubleshooting of electrical system (E-mode).......................................................................................................................1433 Before troubleshooting of electric system.......................................................................................................................1435 Contents of troubleshooting table...............................................................................................................................1436 E-1 Engine does not start.......................................................................................................................................1437 E-2 Automatic preheating does not operate.......................................................................................................................1440 E-3 Machine monitor does not display all, when starting switch is turned ON.....................................................................................1444 E-4 Machine monitor does not operate when starting switch is OFF................................................................................................1446 E-5 Alarm buzzer does not sound.................................................................................................................................1448 E-6 Alarm buzzer does not stop sounding.........................................................................................................................1450 E-7 Gauges of machine monitor, caution lamps or character display section do not display properly...............................................................1451 E-8 A selection of the display in character display section cannot be changed...................................................................................1453 E-9 Power mode selecting function does not operate properly.....................................................................................................1456 E-10 AISS function does not operate properly....................................................................................................................1457 E-11 Seat belt caution lamp does not display properly...........................................................................................................1458 E-12 Turn signal lamp or turning lamp (hazard lamp) do not work properly........................................................................................1459 E-13 Night illumination (lighting) does not work properly.......................................................................................................1462 E-14 Emergency steering does not operate........................................................................................................................1474 E-15 Hoist lever does not operate normally......................................................................................................................1480 E-16 Power supply system (Air conditioner does not operate).....................................................................................................1482 E-17 Compressor and refrigerant system (Air is not cooled)......................................................................................................1484 E-18 Blower motor system (Air does not come out or air flow is abnormal)........................................................................................1486 Troubleshooting of hydraulic and mechanical system (H-mode).........................................................................................................1489 Contents of troubleshooting table...............................................................................................................................1491 H-1 Machine does not start......................................................................................................................................1492 H-2 Machine does not travel smoothly (hunting)..................................................................................................................1494 H-3 Lockup cannot be cancelled..................................................................................................................................1494 H-4 Excessive shock when starting or shifting excessive.........................................................................................................1495 H-5 Transmission does not shift up..............................................................................................................................1496 H-6 Machine lacks power or speed when traveling.................................................................................................................1498 H-7 Time lag is excessive when starting or shifting gear........................................................................................................1502 H-8 Torque converter oil temperature is high....................................................................................................................1504 H-9 Torque converter oil pressure is low........................................................................................................................1505 H-10 Front brake is ineffective.................................................................................................................................1506 H-11 Rear brake is ineffective..................................................................................................................................1507 H-12 Steering wheel is heavy....................................................................................................................................1508 H-13 Steering wheel does not work...............................................................................................................................1509 H-14 Steering wheel vibrates....................................................................................................................................1510 H-15 Dump body lifting speed is slow............................................................................................................................1511 H-16 Dump body does not work....................................................................................................................................1512 H-17 Excessive hydraulic drift of dump body.....................................................................................................................1513 Troubleshooting of engine (S-mode)..................................................................................................................................1515 Method of using troubleshooting charts..........................................................................................................................1517 S-1 Starting performance is poor................................................................................................................................1520 S-2 Engine does not start.......................................................................................................................................1521 S-3 Engine does not pick up smoothly............................................................................................................................1524 S-4 Engine stops during operations..............................................................................................................................1525 S-5 Engine does not rotate smoothly.............................................................................................................................1526 S-6 Engine lacks output (or lacks power)........................................................................................................................1527 S-7 Exhaust smoke is black (incomplete combustion)..............................................................................................................1529 S-8 Oil consumption is excessive (or exhaust smoke is blue).....................................................................................................1530 S-9 Oil becomes contaminated quickly............................................................................................................................1531 S-10 Fuel consumption is excessive..............................................................................................................................1532 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)......................................................................................1533 S-12 Oil pressure drops.........................................................................................................................................1534 S-13 Oil level rises (Entry of coolant or fuel).................................................................................................................1535 S-14 Coolant temperature becomes too high (overheating).........................................................................................................1536 S-15 Abnormal noise is made.....................................................................................................................................1537 S-16 Vibration is excessive.....................................................................................................................................1538 50 Disassembly and assembly.............................................................................................................................................1541 General information on disassembly and assembly.....................................................................................................................1541 How to read this manual.........................................................................................................................................1542 Coating materials list..........................................................................................................................................1544 Special tool list...............................................................................................................................................1547 Sketches of special tools.......................................................................................................................................1550 Engine and cooling system...........................................................................................................................................1557 Removal and installation of fuel supply pump assembly...........................................................................................................1558 Removal and installation of fuel injector assembly..............................................................................................................1560 Removal and installation of cylinder head assembly..............................................................................................................1561 Removal and installation of engine hood assembly................................................................................................................1574 Removal and installation of radiator assembly...................................................................................................................1575 Removal and installation of engine assembly.....................................................................................................................1584 Removal and installation of engine front oil seal...............................................................................................................1589 Removal and installation of engine rear oil seal................................................................................................................1592 Power train, Part 1.................................................................................................................................................1597 Removal and installation of front drive shaft...................................................................................................................1598 Removal and installation of rear drive shaft....................................................................................................................1600 Removal and installation of output shaft assembly...............................................................................................................1601 Disassembly and assembly of damper assembly.....................................................................................................................1606 Removal and installation of torque converter and transmission assembly..........................................................................................1608 Disconnection and connection of torque converter assembly and transmission assembly.............................................................................1611 Disassembly and assembly of torque converter PTO assembly.......................................................................................................1618 Disassembly and assembly of transmission assembly...............................................................................................................1631 Power train, Part 2.................................................................................................................................................1665 Removal and installation of final drive carrier assembly........................................................................................................1666 Disassembly and assembly of final drive carrier assembly........................................................................................................1668 Removal and installation of differential assembly...............................................................................................................1670 Disassembly and assembly of differential assembly...............................................................................................................1673 Steering system.....................................................................................................................................................1687 Removal and installation of steering cylinder assembly..........................................................................................................1688 Disassembly and assembly of steering cylinder assembly..........................................................................................................1689 Removal and installation of steering valve assembly.............................................................................................................1693 Disassembly and assembly of steering valve assembly.............................................................................................................1694 Brake system........................................................................................................................................................1707 Removal and installation of front wheel hub and brake assembly..................................................................................................1708 Disassembly and assembly of front wheel hub and brake assembly..................................................................................................1712 Removal and installation of final drive and rear brake assembly.................................................................................................1720 Disassembly and assembly of final drive and rear brake assembly.................................................................................................1722 Undercarriage and frame.............................................................................................................................................1737 Removal and installation of front wheel assembly................................................................................................................1738 Removal and installation of rear wheel assembly.................................................................................................................1740 Removal and installation of front suspension cylinder assembly..................................................................................................1742 Disassembly and assembly of front suspension cylinder assembly (cylinder with buffer ring)......................................................................1744 Removal and installation of king pin............................................................................................................................1747 Removal and installation of rear suspension cylinder assembly...................................................................................................1749 Disassembly and assembly of rear suspension cylinder assembly...................................................................................................1750 Hydraulic system....................................................................................................................................................1755 Removal and installation of hoist valve assembly................................................................................................................1756 Disassembly and assembly of hoist valve assembly................................................................................................................1757 Disassembly and assembly of hoist cylinder assembly.............................................................................................................1759 Body................................................................................................................................................................1763 Removal and installation of body assembly.......................................................................................................................1764 Cab and its attachments.............................................................................................................................................1769 Disassembly and assembly of operatorβs seat assembly............................................................................................................1770 Removal and installation of air conditioner unit assembly.......................................................................................................1780 Electrical system...................................................................................................................................................1783 Removal and installation of engine controller assembly..........................................................................................................1784 Removal and installation of transmission controller assembly....................................................................................................1784 Removal and installation of retarder controller assembly........................................................................................................1785 Removal and installation of ABS controller assembly.............................................................................................................1785 Removal and installation of VHMS controller assembly............................................................................................................1786 90 Diagrams and drawings................................................................................................................................................1789 Hydraulic diagrams and drawings.....................................................................................................................................1789 Power train hydraulic circuit diagram...........................................................................................................................1791 Steering and hoist hydraulic circuit diagram....................................................................................................................1792 Brake hydraulic circuit diagram.................................................................................................................................1793 Brake hydraulic circuit diagram (ASR specification).............................................................................................................1794 Brake hydraulic circuit diagram (ABS specification).............................................................................................................1795 Brake hydraulic circuit diagram (ASR and ABS specification).....................................................................................................1796 Electrical diagrams and drawings....................................................................................................................................1799 Electrical circuit diagram for outside cab (1/3)................................................................................................................1801 Electrical circuit diagram for outside cab (2/3)................................................................................................................1802 Electrical circuit diagram for outside cab (3/3)................................................................................................................1803 Electrical circuit diagram for inside cab (1/3).................................................................................................................1804 Electrical circuit diagram for inside cab (2/3).................................................................................................................1805 Electrical circuit diagram for inside cab (3/3).................................................................................................................1806 Electrical circuit diagram for VHMS (If equipped)...............................................................................................................1807 Electrical circuit diagram for ABS (Outside cab) (If equipped)..................................................................................................1808 Electrical circuit diagram for ABS (Inside cab) (If equipped)...................................................................................................1809 Electrical circuit diagram for ASR (If equipped)................................................................................................................1810 Air conditioner electrical circuit diagram (If equipped)........................................................................................................1811 Electrical circuit diagram for auto greasing (If equipped)......................................................................................................1812 Connectors table and arrangement drawing........................................................................................................................1814
PLEASE NOTE:
β¦ This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
β¦ You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
β¦ Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
