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Komatsu HD785-7 Dump Truck Shop Manual SEN01274-04-N1-00 PDF
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Komatsu HD785-7 Dump Truck Shop Manual SEN01274-04-N1-00 – PDF DOWNLOAD
SERIAL NUMBERS N10001 – N10560
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Description
Komatsu HD785-7 Dump Truck Shop Manual SEN01274-04-N1-00 – PDF DOWNLOAD
FILE DETAILS:
Komatsu HD785-7 Dump Truck Shop Manual SEN01274-04-N1-00 – PDF DOWNLOAD
Language : English
Pages : 1438
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Komatsu HD785-7 Dump Truck Shop Manual SEN01274-04-N1-00 – PDF DOWNLOAD
SERIAL NUMBERS N10001 – N10560
00 INDEX AND FOREWORD 0
INDEX 2
COMPOSITION OF SHOP MANUAL 3
TABLE OF CONTENTS 5
FOREWORD AND GENERAL INFORMATION 20
SAFETY NOTICE 21
HOW TO READ THE SHOP MANUAL 26
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 28
HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT 30
HOW TO READ ELECTRIC WIRE CODE 42
PRECAUTIONS WHEN CARRYING OUT OPERATION 45
METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER 48
STANDARD TIGHTENING TORQUE TABLE 51
CONVERSION TABLE 55
01 SPECIFICATION 0
SPECIFICATION AND TECHNICAL DATA 62
SPECIFICATION DRAWING 63
SPECIFICATIONS 64
WEIGHT TABLE 67
FUEL, COOLANT AND LUBRICANTS 68
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 0
ENGINE AND COOLING SYSTEM 72
RADIATOR, BRAKE, TORQUE CONVERTER OIL COOLER, AFTERCOOLER, STEERING, HOIST OIL COOLER 73
POWER TRAIN, PART 1 78
POWER TRAIN SKELETON 79
OUTPUT SHAFT 81
DRIVE SHAFT 83
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING 85
BRAKE COOLING OIL CONTROL VALVE (BCV) 87
TORQUE CONVERTER 88
TORQUE CONVERTER VALVE 96
TRANSMISSION 99
TRANSMISSION CONTROL VALVE 127
ECMV 129
LUBRICATING OIL AMOUNT SELECTOR VALVE 136
POWER TRAIN, PART 2 140
AXLE 141
DIFFERENTIAL 143
FINAL DRIVE 144
WHEELS 145
STEERING SYSTEM 148
STEERING COLUMN 149
STEERING LINKAGE 150
BRAKE SYSTEM 154
BRAKE PIPING 155
BRAKE VALVE 157
SECONDARY BRAKE VALVE 160
ACCUMULATOR CHARGE VALVE 161
ACCUMULATOR 165
SLACK ADJUSTER 166
BRAKE, PARKING BRAKE 170
PARKING BRAKE SOLENOID 176
SOLENOID VALVE 177
EXHAUST BRAKE 179
UNDERCARRIAGE AND FRAME 182
SUSPENSION 183
SUSPENSION CYLINDER 185
REAR AXLE SUPPORT 193
HYDRAULIC SYSTEM 196
STEERING AND HOIST HYDRAULIC PIPING 197
STEERING, HOIST FILTER (HIGH PRESSURE CIRCUIT) 199
DUMP BODY CONTROL 201
HYDRAULIC TANK 203
STEERING VALVE 204
CROSSOVER RELIEF VALVE 208
STEERING CYLINDER 209
STEERING CONTROL VALVE 210
HOIST VALVE 219
DUMP CONTROL VALVE (EPC VALVE) 225
HOIST CYLINDER 226
HYDRAULIC PUMP 227
CAB AND ITS ATTACHMENTS 232
ROPS CAB 233
AIR CONDITIONER 234
REAR VIEW MONITOR 243
CONTROLLER RELATED 246
ELECTRICAL SYSTEM, PART 1 248
MACHINE MONITOR SYSTEM 249
ELECTRICAL SYSTEM, PART 2 274
AUTOMATIC SHIFT CONTROL SYSTEM 275
AUTOMATIC EMERGENCY STEERING SYSTEM 293
AUTOMATIC SUSPENSION SYSTEM 297
RETARDER CONTROL SYSTEM 300
DUMP CONTROL LEVER 313
ELECTRICAL SYSTEM, PART 3 318
VHMS CONTROLLER RELATED 319
ABS/ASR SYSTEM 345
ALTITUDE SETTING FUNCTION 363
ELECTRICAL SYSTEM, PART 4 368
SENSORS, SWITCHES 369
20 STANDARD VALUE TABLE 0
STANDARD SERVICE VALUE TABLE 386
STANDARD VALUE TABLE FOR ENGINE 387
STANDARD VALUE TABLE FOR MACHINE 389
30 TESTING AND ADJUSTING 0
TESTING AND ADJUSTING, PART 1 400
TESTING AND ADJUSTING TOOLS LIST 402
TESTING ENGINE SPEED 408
TESTING AIR SUPPLY PRESSURE (BOOST PRESSURE) 409
TESTING EXHAUST TEMPERATURE 411
TESTING EXHAUST GAS COLOR 413
ADJUSTMENT OF VALVE CLEARANCE 415
TESTING COMPRESSION PRESSURE 417
TESTING BLOW-BY PRESSURE 419
TESTING ENGINE OIL PRESSURE 420
HANDLING OF FUEL SYSTEM DEVICES 421
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM 421
TESTING FUEL PRESSURE 422
REDUCED CYLINDER MODE OPERATION 423
NO-INJECTION CRANKING 423
TESTING LEAKAGE-FROM PRESSURE LIMITER AND RETURN RATE FROM INJECTOR 424
BLEEDING AIR FROM FUEL CIRCUIT (STANDARD SPEC ) 427
BLEEDING AIR FROM FUEL CIRCUIT (EXTRA LOW-GRADE FUEL SPEC ) 429
TESTING THE FUEL CIRCUIT FOR LEAKAGE 431
REPLACEMENT AND ADJUSTMENT OF FAN BELT 432
TESTING AND ADJUSTING ALTERNATOR BELT TENSION 433
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT 434
TESTING AND ADJUSTING, PART 2 436
TESTING TORQUE CONVERTER STALL SPEED 438
TESTING POWER TRAIN OIL PRESSURE 439
ADJUSTING TRANSMISSION SPEED SENSOR 447
TESTING AND ADJUSTING BRAKE OIL PRESSURE 448
TESTING OF ACCUMULATOR NITROGEN GAS PRESSURE AND PROCEDURE FOR CHARGING ACCUMULATOR WITH NITROGEN GAS 451
TESTING BRAKE PERFORMANCE 454
BLEEDING AIR FROM BRAKE CIRCUIT 456
BLEEDING AIR FROM ASR CIRCUIT (IF EQUIPPED) 458
TESTING WEAR OF FRONT BRAKE DISC 459
TESTING WEAR OF REAR BRAKE DISC 460
METHOD OF RELEASING PARKING BRAKE IN AN EMERGENCY 461
TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER 462
TESTING AND ADJUSTING REAR SUSPENSION CYLINDER 466
TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION) 470
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING, HOIST CIRCUIT 471
TESTING AND ADJUSTING OIL PRESSURE IN DUMP EPC CIRCUIT 474
AIR BLEEDING FROM STEERING CYLINDER 475
PROCEDURE FOR RAISING DUMP BODY IN EMERGENCY 476
ADJUSTING BODY POSITIONER SENSOR 477
HANDLING OF VOLTAGE CIRCUIT OF ENGINE CONTROLLER 479
ADJUSTING TRANSMISSION CONTROLLER 479
METHOD FOR EMERGENCY ESCAPE AT ELECTRICAL SYSTEM FAILURE 480
TESTING AND ADJUSTING, PART 3 485
SETTING AND ADJUSTING OF DEVICES 486
SPECIAL FUNCTIONS OF MACHINE MONITOR (EMMS) 498
TESTING AND ADJUSTING, PART 4 522
SPECIAL FUNCTIONS OF MACHINE MONITOR (EMMS) 523
TESTING AND ADJUSTING, PART 5 566
VHMS CONTROLLER INITIAL SETTING PROCEDURE 567
PRECAUTIONS FOR REPLACING VHMS CONTROLLER 588
PM CLINIC CHECK SHEET 594
INITIAL SETTING OF PAYLOAD METER 598
SETTING OF PAYLOAD METER BUILT IN VHMS 599
40 TROUBLESHOOTING 0
FAILURE CODE TABLE AND FUSE LOCATIONS 608
FAILURE CODES TABLE 609
FUSE LOCATIONS 623
GENERAL INFORMATION ON TROUBLESHOOTING 629
POINTS TO REMEMBER WHEN TROUBLESHOOTING 630
SEQUENCE OF EVENTS IN TROUBLESHOOTING 631
CHECK BEFORE TROUBLESHOOTING 632
CLASSIFICATION AND PROCEDURES FOR TROUBLESHOOTING 633
CONTENTS OF TROUBLESHOOTING TABLE 634
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 636
T-ADAPTER BOX AND T-ADAPTER TABLE 665
TROUBLESHOOTING BY FAILURE CODE, PART 1 669
FAILURE CODE [1500L0] DUAL ENGAGEMENT 671
FAILURE CODE [15B0NX] TRANSMISSION OIL FILTER: CLOGGING 672
FAILURE CODE [15F0KM] R™ F SHIFTING ABUSE 1: MISTAKE IN OPERATION 674
FAILURE CODE [15F0MB] R™ F SHIFTING ABUSE 2: MISTAKE IN OPERATION 674
FAILURE CODE [15F7KM] FORWARD CLUTCH DISK ABUSE: MISTAKE IN OPERATION OR SETTING 675
FAILURE CODE [15G0MW] R CLUTCH: SLIPPING 676
FAILURE CODE [15G7KM] REVERSE CLUTCH DISK ABUSE: MISTAKE IN OPERATION OR SETTING 678
FAILURE CODE [15H0MW] HI CLUTCH: SLIPPING 679
FAILURE CODE [15J0MW] LO CLUTCH: SLIPPING 681
FAILURE CODE [15K0MW] 1ST CLUTCH: SLIPPING 683
FAILURE CODE [15L0MW] 2ND CLUTCH: SLIPPING 685
FAILURE CODE [15M0MW] 3RD CLUTCH: SLIPPING 687
FAILURE CODE [15N0MW] 4TH CLUTCH: SLIPPING 689
FAILURE CODE [15SBL1] R CLUTCH SOLENOID: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF 691
FAILURE CODE [15SBMA] R CLUTCH SOLENOID: MALFUNCTION 693
FAILURE CODE [15SCL1] HI CLUTCH SOLENOID: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF 695
FAILURE CODE [15SCMA] HI CLUTCH SOLENOID: MALFUNCTION 698
FAILURE CODE [15SDL1] LO CLUTCH SOLENOID: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF 700
FAILURE CODE [15SDMA] LO CLUTCH SOLENOID: MALFUNCTION 703
FAILURE CODE [15SEL1] 1ST CLUTCH SOLENOID: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF 705
FAILURE CODE [15SEMA] 1ST CLUTCH SOLENOID: MALFUNCTION 708
TROUBLESHOOTING BY FAILURE CODE, PART 2 711
FAILURE CODE [15SFL1] 2ND CLUTCH SOLENOID: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF 713
FAILURE CODE [15SFMA] 2ND CLUTCH SOLENOID: MALFUNCTION 716
FAILURE CODE [15SGL1] 3RD CLUTCH SOLENOID: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF 718
FAILURE CODE [15SGMA] 3RD CLUTCH SOLENOID: MALFUNCTION 721
FAILURE CODE [15SHL1] 4TH CLUTCH SOLENOID: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF 723
FAILURE CODE [15SHMA] 4TH CLUTCH SOLENOID: MALFUNCTION 726
FAILURE CODE [15SJMA] LOCKUP CLUTCH SOLENOID: MALFUNCTION 728
FAILURE CODE [2F00KM] PARKING BRAKE: MISTAKE IN OPERATION OR SETTING 729
FAILURE CODE [2G42ZG] ACCUMULATOR: OIL PRESSURE REDUCTION (FRONT) 732
FAILURE CODE [2G43ZG] ACCUMULATOR: OIL PRESSURE REDUCTION (REAR) 732
FAILURE CODE [989A00] ENGINE OVER RUN PREVENTION COMMAND SIGNAL: OPERATING 733
FAILURE CODE [989D00] REAR SECTION TIPPING OVER ALARM: ALARM IS ACTIVATED 733
FAILURE CODE [A570NX] ENGINE OIL FILTER: CLOGGING 734
FAILURE CODE [AA10NX] AIR CLEANER ELEMENT: CLOGGING 736
FAILURE CODE [AB00MA] ALTERNATOR: MALFUNCTION 738
FAILURE CODE [B@BAZG] ABNORMAL LOWERING OF ENGINE OIL PRESSURE: LOWERING OF OIL PRESSURE 740
FAILURE CODE [B@BAZK] ENGINE OIL: LEVEL TOO LOW 742
FAILURE CODE [B@BCNS] ENGINE: OVERHEAT 744
FAILURE CODE [B@BCZK] LOWERING OF RADIATOR COOLANT: LOWERING OF LEVEL 746
FAILURE CODE [B@BFZK] LOWERING OF FUEL LEVEL 748
FAILURE CODE [B@C6NS] BRAKE COOLING OIL: OVERHEATING (FRONT) 749
FAILURE CODE [B@C7NS] BRAKE COOLING OIL: OVERHEATING (REAR) 751
FAILURE CODE [B@CENS] OVERHEATING OF TORQUE CONVERTER OIL 753
FAILURE CODE [B@GAZK] BATTERY ELECTROLYTE LEVEL: LOWERING OF LEVEL 754
FAILURE CODE [B@JANS] STEERING OIL: OVERHEAT 755
TROUBLESHOOTING BY FAILURE CODE, PART 3 757
FAILURE CODE [CA111] ENGINE CONTROLLER (LEFT BANK): INTERNAL ABNORMALITY 759
FAILURE CODE [CB111] ENGINE CONTROLLER (RIGHT BANK): INTERNAL ABNORMALITY 761
FAILURE CODE [CA115] ABNORMAL ENGINE NE AND BKUP SPEED SENSORS (AT LEFT BANK): ABNORMAL SPEED SENSOR SIGNAL 763
FAILURE CODE [CB115] ABNORMAL ENGINE NE AND BKUP SPEED SENSORS (AT RIGHT BANK): ABNORMAL SPEED SENSOR SIGNAL 764
FAILURE CODE [CA122] CHARGE PRESSURE SENSOR TOO HIGH (AT LEFT BANK ONLY): EXCESSIVELY HIGH VOLTAGE DETECTED 765
FAILURE CODE [CA123] CHARGE PRESSURE SENSOR TOO LOW (AT LEFT BANK ONLY): EXCESSIVELY LOW VOLTAGE DETECTED 767
FAILURE CODE [CA131] THROTTLE SENSOR HIGH ERROR 768
FAILURE CODE [CA132] THROTTLE SENSOR LOW ERROR 770
FAILURE CODE [CA135] OIL PRESSURE SENSOR TOO HIGH (AT LEFT BANK ONLY): EXCESSIVELY HIGH VOLTAGE DETECTED 771
FAILURE CODE [CA141] OIL PRESSURE SENSOR TOO LOW (AT LEFT BANK ONLY): EXCESSIVELY LOW VOLTAGE DETECTED 773
FAILURE CODE [CA144] COOLANT TEMPERATURE SENSOR TOO HIGH: EXCESSIVELY HIGH VOLTAGE DETECTED 774
FAILURE CODE [CA145] COOLANT TEMPERATURE SENSOR TOO LOW (AT LEFT BANK ONLY): EXCESSIVELY LOW VOLTAGE DETECTED 776
FAILURE CODE [CA153] CHARGE TEMPERATURE SENSOR TOO HIGH (AT LEFT BANK ONLY): EXCESSIVELY HIGH VOLTAGE DETECTED 778
FAILURE CODE [CA154] CHARGE TEMPERATURE SENSOR TOO LOW (AT LEFT BANK ONLY): EXCESSIVELY LOW VOLTAGE DETECTED 780
FAILURE CODE [CA187] SENSOR POWER SUPPLY (2) ABNORMALLY LOW LEVEL (LEFT BANK): LOW VOLTAGE DETECTION 782
FAILURE CODE [CB187] SENSOR POWER SUPPLY (2) ABNORMALLY LOW LEVEL (RIGHT BANK): LOW VOLTAGE DETECTION 782
FAILURE CODE [CA212] ENGINE OIL TEMPERATURE SENSOR ABNORMALLY HIGH LEVEL (ONLY LEFT BANK): HIGH VOLTAGE DETECTION 783
FAILURE CODE [CA213] ENGINE OIL TEMPERATURE SENSOR ABNORMALLY LOW LEVEL (ONLY LEFT BANK): LOW VOLTAGE DETECTION 785
FAILURE CODE [CA221] ATMOSPHERIC PRESSURE SENSOR TOO HIGH (AT LEFT BANK ONLY): EXCESSIVELY HIGH VOLTAGE DETECTED 786
FAILURE CODE [CA222] ATMOSPHERIC PRESSURE SENSOR TOO LOW (AT LEFT BANK ONLY): EXCESSIVELY LOW VOLTAGE DETECTED 788
FAILURE CODE [CA227] SENSOR POWER SOURCE (2) TOO HIGH (AT LEFT BANK): EXCESSIVELY HIGH VOLTAGE DETECTED 789
FAILURE CODE [CB227] SENSOR POWER SUPPLY (2) ABNORMALLY HIGH LEVEL (RIGHT BANK): HIGH VOLTAGE DETECTION 791
FAILURE CODE [CA234] ENGINE OVER SPEED (AT LEFT BANK ONLY): EXCESSIVELY HIGH SPEED 793
FAILURE CODE [CA238] ABNORMAL POWER SOURCE FOR NE SPEED SENSOR (AT LEFT BANK ONLY): EXCESSIVELY LOW VOLTAGE DETECTED 794
FAILURE CODE [CB238] ABNORMAL POWER SOURCE FOR NE SPEED SENSOR (AT RIGHT BANK ONLY): EXCESSIVELY LOW VOLTAGE DETECTED 796
FAILURE CODE [CA263] FUEL TEMPERATURE SENSOR TOO HIGH (AT LEFT BANK): EXCESSIVELY HIGH VOLTAGE DETECTED 798
FAILURE CODE [CB263] FUEL TEMPERATURE SENSOR TOO HIGH (AT RIGHT BANK): EXCESSIVELY HIGH VOLTAGE DETECTED 800
FAILURE CODE [CA265] FUEL TEMPERATURE SENSOR ABNORMALLY LOW LEVEL (LEFT BANK): LOW VOLTAGE DETECTION 802
FAILURE CODE [CB265] FUEL TEMPERATURE SENSOR ABNORMALLY LOW LEVEL (RIGHT BANK): LOW VOLTAGE DETECTION 802
FAILURE CODE [CA271] PCV1 SHORT CIRCUIT (LEFT BANK): SHORT CIRCUIT 803
FAILURE CODE [CB271] PCV1 SHORT CIRCUIT (RIGHT BANK): SHORT CIRCUIT 804
FAILURE CODE [CA272] PCV1 DISCONNECTION (LEFT BANK): DISCONNECTION 805
FAILURE CODE [CB272] PCV1 DISCONNECTION (RIGHT BANK): DISCONNECTION 806
FAILURE CODE [CA273] PCV2 SHORT CIRCUIT (LEFT BANK): SHORT CIRCUIT 807
FAILURE CODE [CB273] PCV2 SHORT CIRCUIT (RIGHT BANK): SHORT CIRCUIT 808
FAILURE CODE [CA274] PCV2 DISCONNECTION (LEFT BANK): DISCONNECTION 809
FAILURE CODE [CB274] PCV2 DISCONNECTION (RIGHT BANK): DISCONNECTION 810
TROUBLESHOOTING BY FAILURE CODE, PART 4 812
FAILURE CODE [CA322] INJECTOR NO 1 (L/B NO 1) SYSTEM DISCONNECTION OR SHORT CIRCUIT (AT LEFT BANK): DISCONNECTION, SHORT CIRCUIT 814
FAILURE CODE [CA323] INJECTOR NO 5 (L/B NO 5) SYSTEM DISCONNECTION OR SHORT CIRCUIT (AT LEFT BANK): DISCONNECTION, SHORT CIRCUIT 816
FAILURE CODE [CA324] INJECTOR NO 3 (L/B NO 3) SYSTEM DISCONNECTION OR SHORT CIRCUIT (AT LEFT BANK): DISCONNECTION, SHORT CIRCUIT 818
FAILURE CODE [CA325] INJECTOR NO 6 (L/B NO 6) SYSTEM DISCONNECTION OR SHORT CIRCUIT (AT LEFT BANK): DISCONNECTION, SHORT CIRCUIT 820
FAILURE CODE [CA331] INJECTOR NO 2 (L/B NO 2) SYSTEM DISCONNECTION OR SHORT CIRCUIT (AT LEFT BANK): DISCONNECTION, SHORT CIRCUIT 822
FAILURE CODE [CA332] INJECTOR NO 4 (L/B NO 4) SYSTEM DISCONNECTION OR SHORT CIRCUIT (AT LEFT BANK):DISCONNECTION, SHORT CIRCUIT 824
FAILURE CODE [CA342] ENGINE CONTROLLER DATA MISMATCH (LEFT BANK): MISMATCH 826
FAILURE CODE [CB342] ENGINE CONTROLLER DATA MISMATCH (RIGHT BANK): MISMATCH 826
FAILURE CODE [CA351] ABNORMAL INJECTOR DRIVE CIRCUIT (AT LEFT BANK): ABNORMAL CIRCUIT 827
FAILURE CODE [CB351] INJECTOR DRIVE CIRCUIT ABNORMALITY (RIGHT BANK): CIRCUIT ABNORMALITY 829
FAILURE CODE [CA352] SENSOR POWER SUPPLY (1) ABNORMALLY LOW LEVEL (LEFT BANK):LOW VOLTAGE DETECTION 831
FAILURE CODE [CB352] SENSOR POWER SUPPLY (1) ABNORMALLY LOW LEVEL (RIGHT BANK): LOW VOLTAGE DETECTION 831
FAILURE CODE [CA386] SENSOR POWER SUPPLY (1) ABNORMALLY HIGH LEVEL (LEFT BANK): HIGH VOLTAGE DETECTION 832
FAILURE CODE [CB386] SENSOR POWER SUPPLY (1) ABNORMALLY HIGH LEVEL (RIGHT BANK): HIGH VOLTAGE DETECTION 834
FAILURE CODE [CA431] TROUBLE IN IDLE VALIDATION SWITCH 836
FAILURE CODE [CA432] IDLE VALIDATION ACTION ERROR 838
FAILURE CODE [CA441] POWER SUPPLY VOLTAGE ABNORMALLY LOW LEVEL (LEFT BANK): LOW VOLTAGE DETECTION 839
FAILURE CODE [CB441] POWER SUPPLY VOLTAGE ABNORMALLY LOW LEVEL (RIGHT BANK): LOW VOLTAGE DETECTION 839
FAILURE CODE [CA442] POWER SUPPLY VOLTAGE ABNORMALLY HIGH LEVEL (LEFT BANK): HIGH VOLTAGE DETECTION 840
FAILURE CODE [CB442] POWER SUPPLY VOLTAGE ABNORMALLY HIGH LEVEL (RIGHT BANK): HIGH VOLTAGE DETECTION 840
FAILURE CODE [CA449] COMMON RAIL ABNORMALLY HIGH PRESSURE (2) (LEFT BANK): ABNORMALLY HIGH PRESSURE OCCURRENCE 841
FAILURE CODE [CB449] COMMON RAIL ABNORMALLY HIGH PRESSURE (2) (RIGHT BANK): ABNORMALLY HIGH PRESSURE OCCURRENCE 841
FAILURE CODE [CA451] COMMON RAIL PRESSURE SENSOR TOO HIGH (AT LEFT BANK): EXCESSIVELY HIGH VOLTAGE DETECTED 842
FAILURE CODE [CB451] COMMON RAIL PRESSURE SENSOR ABNORMALLY HIGH LEVEL (RIGHT BANK): HIGH VOLTAGE DETECTION 844
FAILURE CODE [CA452] COMMON RAIL PRESSURE SENSOR ABNORMALLY LOW LEVEL (LEFT BANK): ABNORMALLY LOW VOLTAGE DETECTION 846
FAILURE CODE [CB452] COMMON RAIL PRESSURE SENSOR ABNORMALLY LOW LEVEL (RIGHT BANK):ABNORMALLY LOW VOLTAGE DETECTION 846
FAILURE CODE [CA553] COMMON RAIL PRESSURE TOO HIGH (1) (AT LEFT BANK):EXCESSIVELY HIGH PRESSURE DETECTED 847
FAILURE CODE [CB553] COMMON RAIL PRESSURE TOO HIGH (1) (AT RIGHT BANK): EXCESSIVELY HIGH PRESSURE DETECTED 848
FAILURE CODE [CA554] IN-RANGE ERROR IN COMMON RAIL PRESSURE SENSOR (AT LEFT BANK): IN-RANGE ERROR 849
FAILURE CODE [CB554] IN-RANGE ERROR IN COMMON RAIL PRESSURE SENSOR (AT RIGHT BANK): IN-RANGE ERROR 849
FAILURE CODE [CA559] LOSS OF PRESSURE FEED FROM SUPPLY PUMP (1) (AT LEFT BANK): LOSS OF PRESSURE FEED DETECTED 850
FAILURE CODE [CB559] LOSS OF PRESSURE FEED FROM SUPPLY PUMP (1) (AT RIGHT BANK): LOSS OF PRESSURE FEED DETECTED 854
FAILURE CODE [CA689] ABNORMAL ENGINE NE SPEED SENSOR (AT LEFT BANK): ABNORMAL SIGNAL 858
FAILURE CODE [CB689] ABNORMAL ENGINE NE SPEED SENSOR (AT RIGHT BANK): ABNORMAL SIGNAL 860
FAILURE CODE [CA691] INTAKE AIR TEMPERATURE SENSOR ABNORMALLY HIGH LEVEL (ONLY LEFT BANK):HIGH VOLTAGE DETECTION 862
FAILURE CODE [CA692] INTAKE AIR TEMPERATURE SENSOR ABNORMALLY LOW LEVEL (ONLY LEFT BANK): LOW VOLTAGE DETECTION 864
FAILURE CODE [CA731] ABNORMAL ENGINE BKUP SPEED SENSOR PHASE (AT LEFT BANK): ABNORMAL PHASE 865
FAILURE CODE [CB731] ABNORMAL ENGINE BKUP SPEED SENSOR PHASE (AT RIGHT BANK): ABNORMAL PHASE 865
TROUBLESHOOTING BY FAILURE CODE, PART 5 867
FAILURE CODE [CA757] LOSS OF ALL ENGINE CONTROLLER DATA (AT LEFT BANK): LOSS OF ALL DATA 869
FAILURE CODE [CB757] LOSS OF ALL ENGINE CONTROLLER DATA (AT RIGHT BANK): LOSS OF ALL DATA 869
FAILURE CODE [CA778] ABNORMAL ENGINE BKUP SPEED SENSOR (AT LEFT BANK): ABNORMAL BKUP SIGNAL 870
FAILURE CODE [CB778] ENGINE BKUP SPEED SENSOR ABNORMALITY (RIGHT BANK): BKUP SIGNAL ERROR 872
FAILURE CODE [CA781] INTER-MULTICONTROLLER COMMUNICATION ERROR (LEFT BANK): COMMUNICATION ERROR 874
FAILURE CODE [CB781] INTER-MULTICONTROLLER COMMUNICATION ERROR (RIGHT BANK): COMMUNICATION ERROR 876
FAILURE CODE [CA1257] MULTICONTROLLER DISTINCTION WIRING HARNESS KEY ERROR (LEFT BANK):DISTINCTION ERROR 877
FAILURE CODE [CB1257] MULTICONTROLLER DISTINCTION WIRING HARNESS KEY ERROR (RIGHT BANK): DISTINCTION ERROR 878
FAILURE CODE [CB1548] INJECTOR #7 (R/B #1) SYSTEM DISCONNECTION/SHORT CIRCUIT (RIGHT BANK): DISCONNECTION/SHORT CIRCUIT 879
FAILURE CODE [CB1549] INJECTOR #8 (R/B #2) SYSTEM DISCONNECTION/SHORT CIRCUIT (RIGHT BANK): DISCONNECTION/SHORT CIRCUIT 881
FAILURE CODE [CB1551] INJECTOR #10 (R/B #4) SYSTEM DISCONNECTION/SHORT CIRCUIT (RIGHT BANK): DISCONNECTION/SHORT CIRCUIT 883
FAILURE CODE [CB1552] INJECTOR #11 (R/B #5) SYSTEM DISCONNECTION/SHORT CIRCUIT (RIGHT BANK): DISCONNECTION/SHORT CIRCUIT 885
FAILURE CODE [CB1553] INJECTOR #12 (R/B #6) SYSTEM DISCONNECTION/SHORT CIRCUIT (RIGHT BANK):DISCONNECTION/SHORT CIRCUIT 887
FAILURE CODE [CB1622] INJECTOR #9 (R/B #3) SYSTEM DISCONNECTION/SHORT CIRCUIT (RIGHT BANK):DISCONNECTION/SHORT CIRCUIT 889
FAILURE CODE [CA1633] KOMNET ABNORMALITY (LEFT BANK): COMMUNICATION ERROR 891
FAILURE CODE [CA2185] THROTTLE SENSOR SUPPLY VOLTAGE HIGH ERROR 893
FAILURE CODE [CA2186] THROTTLE SENSOR POWER SUPPLY LOW ERROR 895
FAILURE CODE [CA2249] LOSS OF PRESSURE FEED FROM SUPPLY PUMP (2) (AT LEFT BANK): LOSS OF PRESSURE FEED DETECTED 896
FAILURE CODE [CB2249] LOSS OF PRESSURE FEED FROM SUPPLY PUMP (2) (AT RIGHT BANK): LOSS OF PRESSURE FEED DETECTED 896
FAILURE CODE [CA2555] INTAKE HEATER RELAY VOLTAGE LOW ERROR (AT LEFT BANK) 897
FAILURE CODE [CA2556] INTAKE HEATER RELAY VOLTAGE HIGH ERROR (AT LEFT BANK) 898
TROUBLESHOOTING BY FAILURE CODE, PART 6 901
FAILURE CODE [D19HKB] STOP LAMP RELAY OUTPUT SYSTEM: SHORT CIRCUIT 903
FAILURE CODE [DAF9KM] WRONG CONNECTION OF CONNECTOR 904
FAILURE CODE [DAFRKR] CAN COMMUNICATION ERROR (MACHINE MONITOR): COMMUNICATION ERROR 905
FAILURE CODE [DAQ0KK] TRANSMISSION CONTROLLER DIRECT POWER SUPPLY: LOWERING OF SOURCE VOLTAGE 908
FAILURE CODE [DAQ0KT] TRANSMISSION CONTROLLER NONVOLATILE MEMORY: ABNORMALITY IN CONTROLLER 910
FAILURE CODE [DAQ2KK] TRANSMISSION CONTROLLER SOLENOID POWER SOURCE: POWER SOURCE VOLTAGE TOO LOW 911
FAILURE CODE [DAQ9KQ] TRANSMISSION CONTROLLER: DISAGREEMENT OF MODEL SELECTION 912
FAILURE CODE [DAQRKR] ABNORMALITY IN CAN COMMUNICATION (TRANSMISSION) 912
FAILURE CODE [DAQRMA] TRANSMISSION CONTROLLER OPTION SETTING: MALFUNCTION 913
FAILURE CODE [DB10KT] RETARDER CONTROLLER NONVOLATILE MEMORY: ABNORMALITY IN CONTROLLER 913
FAILURE CODE [DB12KK] RETARDER CONTROLLER SOLENOID POWER SOURCE: POWER SOURCE SYSTEM TROUBLE 914
FAILURE CODE [DB13KK] RETARDER CONTROLLER BATTERY DIRECT POWER SOURCE: POWER SOURCE VOLTAGE TOO LOW 916
FAILURE CODE [DB19KQ] DISAGREEMENT OF MODEL SELECTION (RETARDER CONTROLLER) 918
FAILURE CODE [DB1RKR] CAN COMMUNICATION (RETARDER CONTROLLER): COMMUNICATION DISABLED 919
FAILURE CODE [DB1RMA] DISAGREEMENT OF OPTION SETTING (RETARDER CONTROLLER) 922
FAILURE CODE [DB2RKR] CAN COMMUNICATION (ENGINE CONTROLLER): COMMUNICATION DISABLED 923
FAILURE CODE [DB2RKR] CAN COMMUNICATION (ENGINE CONTROLLER): COMMUNICATION DISABLED 926
FAILURE CODE [DBBRKR] ABNORMALITY IN CAN COMMUNICATION (VHMS) 929
FAILURE CODE [DBC2KK] ABS CONTROLLER SOLENOID POWER SOURCE: POWER SOURCE SYSTEM TROUBLE 930
FAILURE CODE [DBC3KK] ABS CONTROLLER BATTERY DIRECT POWER SOURCE:POWER SOURCE VOLTAGE TOO LOW 932
FAILURE CODE [DBC9KQ] DISAGREEMENT OF MODEL SELECTION (ABS CONTROLLER) 934
FAILURE CODE [DBCRKR] ABNORMALITY IN CAN COMMUNICATION (ABS) 934
FAILURE CODE [DBCRMA] DISAGREEMENT OF OPTION SETTING (ABS CONTROLLER) 935
FAILURE CODE [DDD7KX] TROUBLE IN TRAVEL SPEED SETTING SWITCH SYSTEM:OUT OF INPUT SIGNAL RANGE 936
FAILURE CODE [DDD8KA] ARSC SYSTEM SWITCH SYSTEM: DISCONNECTION 938
FAILURE CODE [DDD8KB] ARSC SYSTEM SWITCH SYSTEM: SHORT CIRCUIT 940
FAILURE CODE [DDD9KA] ABS SYSTEM SWITCH SYSTEM: DISCONNECTION 942
FAILURE CODE [DDD9KB] ABS SYSTEM SWITCH SYSTEM: SHORT CIRCUIT 944
FAILURE CODE [DDDAKA] ASR SYSTEM SWITCH: DISCONNECTION 946
FAILURE CODE [DDDAKB] ASR SYSTEM SWITCH: SHORT CIRCUIT 948
FAILURE CODE [DDP6L4] SERVICE BRAKE PRESSURE SWITCH TROUBLE (REAR) 950
FAILURE CODE [DDTHKA] HI CLUTCH FILL SWITCH: DISCONNECTION 952
FAILURE CODE [DDTJKA] LO CLUTCH FILL SWITCH: DISCONNECTION 954
FAILURE CODE [DDTKKA] 1ST CLUTCH FILL SWITCH: DISCONNECTION 956
FAILURE CODE [DDTLKA] 2ND CLUTCH FILL SWITCH: DISCONNECTION 958
FAILURE CODE [DDTMKA] 3RD CLUTCH FILL SWITCH: DISCONNECTION 960
FAILURE CODE [DDTNKA] R CLUTCH FILL SWITCH: DISCONNECTION 962
FAILURE CODE [DDTPKA] 4TH CLUTCH FILL SWITCH: DISCONNECTION 964
FAILURE CODE [DF10KA] GEAR SHIFT LEVER: DISCONNECTION 966
FAILURE CODE [DF10KB] GEAR SHIFT LEVER: SHORT CIRCUIT 969
FAILURE CODE [DGF1KX] TRANSMISSION OIL TEMPERATURE SENSOR: OUT OF INPUT SIGNAL RANGE 972
FAILURE CODE [DGR2KB] TROUBLE IN RETARDER OIL TEMPERATURE SENSOR (REAR WHEEL) SYSTEM (DISCONNECTION AND SHORT CIRCUIT) 974
FAILURE CODE [DGR2KZ] TROUBLE IN RETARDER OIL TEMPERATURE SENSOR (REAR WHEEL) SYSTEM (GROUND FAULT) 976
FAILURE CODE [DGR4KB] TROUBLE IN RETARDER OIL TEMPERATURE SENSOR (FRONT WHEEL) SYSTEM (DISCONNECTION AND SHORT CIRCUIT) 978
FAILURE CODE [DGR4KZ] TROUBLE IN RETARDER OIL TEMPERATURE SENSOR (FRONT WHEEL) SYSTEM (GROUND FAULT) 980
FAILURE CODE [DGR6KX] STEERING OIL TEMPERATURE SENSOR: INPUT SIGNAL OUT OF RANGE 982
FAILURE CODE [DGT1KX] TORQUE CONVERTER OIL TEMPERATURE SENSOR: OUT OF INPUT SIGNAL RANGE 984
TROUBLESHOOTING BY FAILURE CODE, PART 7 987
FAILURE CODE [DHP4KY] SUSPENSION PRESSURE SENSOR SYSTEM: SHORT CIRCUIT (RIGHT FRONT) 989
FAILURE CODE [DHP4KZ] SUSPENSION PRESSURE SENSOR SYSTEM: DISCONNECTION OR GROUND FAULT (RIGHT FRONT) 991
FAILURE CODE [DHP5KY] SUSPENSION PRESSURE SENSOR SYSTEM: SHORT CIRCUIT (LEFT FRONT) 992
FAILURE CODE [DHP5KZ] SUSPENSION PRESSURE SENSOR SYSTEM: DISCONNECTION OR GROUND FAULT (LEFT FRONT) 994
FAILURE CODE [DHP6KA] SUSPENSION PRESSURE SENSOR SYSTEM: DISCONNECTION (RIGHT REAR) 995
FAILURE CODE [DHP6KX] FAILURE IN SUSPENSION PRESSURE SENSOR SYSTEM TROUBLE: OUT OF INPUT SIGNAL RANGE (RIGHT REAR) 996
FAILURE CODE [DHP6KY] SUSPENSION PRESSURE SENSOR SYSTEM: SHORT CIRCUIT (RIGHT REAR) 998
FAILURE CODE [DHP6KZ] SUSPENSION PRESSURE SENSOR SYSTEM: DISCONNECTION OR GROUND FAULT (RIGHT REAR) 998
FAILURE CODE [DHP7KA] SUSPENSION PRESSURE SENSOR SYSTEM: DISCONNECTION (LEFT REAR) 999
FAILURE CODE [DHP7KX] FAILURE IN SUSPENSION PRESSURE SENSOR SYSTEM TROUBLE: OUT OF INPUT SIGNAL RANGE (LEFT REAR) 1000
FAILURE CODE [DHP7KY] SUSPENSION PRESSURE SENSOR SYSTEM: SHORT CIRCUIT (LEFT REAR) 1002
FAILURE CODE [DHP7KZ] SUSPENSION PRESSURE SENSOR SYSTEM: DISCONNECTION OR GROUND FAULT (LEFT REAR) 1002
FAILURE CODE [DHT5KX] TORQUE CONVERTER OIL PRESSURE SENSOR: OUT OF INPUT SIGNAL RANGE 1003
FAILURE CODE [DHT5L6] TORQUE CONVERTER OIL PRESSURE SENSOR: DISAGREEMENT OF RUN AND STOP CONDITION WITH SIGNAL 1005
FAILURE CODE [DHU2KX] FRONT ACCUMULATOR OIL PRESSURE SENSOR: OUT OF INPUT SIGNAL RANGE 1007
FAILURE CODE [DHU3KX] REAR ACCUMULATOR OIL PRESSURE SENSOR: OUT OF INPUT SIGNAL RANGE 1009
FAILURE CODE [DJF1KA] FUEL LEVEL SENSOR: DISCONNECTION 1011
FAILURE CODE [DK30KX] STEERING ANGLE POTENTIOMETER: TROUBLE (DISCONNECTION) 1012
FAILURE CODE [DK51L5] TROUBLE IN RETARDER LEVER POTENTIOMETER AND RVS 1013
FAILURE CODE [DK52KX] FAILURE IN HOIST LEVER POTENTIOMETER 1: OUT OF INPUT SIGNAL RANGE 1016
FAILURE CODE [DK53L8] FAILURE IN HOIST LEVER POTENTIOMETER 2: DISAGREEMENT OF ANALOG SIGNAL 1018
FAILURE CODE [DK54KX] BODY POSITIONER SENSOR: OUT OF INPUT SIGNAL RANGE 1019
FAILURE CODE [DKD0L6] FAILURE IN STEERING ANGLE SPEED SENSOR 1021
FAILURE CODE [DKH0KX] PITCH ANGLE SENSOR: OUT OF INPUT SIGNAL RANGE 1023
FAILURE CODE [DKH1KX] PITCH ANGLE SENSOR: ABNORMALITY 1025
FAILURE CODE [DLF1KA] TRANSMISSION INPUT SHAFT SPEED SENSOR: DISCONNECTION 1026
FAILURE CODE [DLF1LC] TRANSMISSION INPUT SHAFT SPEED SENSOR: DISAGREEMENT OF REVOLUTION SPEED SIGNAL 1028
FAILURE CODE [DLF2KA] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: DISCONNECTION 1030
FAILURE CODE [DLF2LC] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: DISAGREEMENT OF REVOLUTION SPEED SIGNAL 1032
TROUBLESHOOTING BY FAILURE CODE, PART 8 1035
FAILURE CODE [DLF8KA] WHEEL SPEED SENSOR: DISCONNECTION (RIGHT REAR) 1037
FAILURE CODE [DLF8L3] WHEEL SPEED SENSOR: DISCONNECTION (RIGHT REAR 1039
FAILURE CODE [DLF8LC] WHEEL SPEED SENSOR: TROUBLE (RIGHT REAR) 1041
FAILURE CODE [DLF8MA] WHEEL SPEED SENSOR: DISCONNECTION (RIGHT REAR) 1041
FAILURE CODE [DLF9KA] WHEEL SPEED SENSOR: DISCONNECTION (LEFT REAR) 1042
FAILURE CODE [DLF9L3] WHEEL SPEED SENSOR: TROUBLE (LEFT REAR) 1044
FAILURE CODE [DLF9LC] WHEEL SPEED SENSOR: TROUBLE (LEFT REAR) 1046
FAILURE CODE [DLF9MA] WHEEL SPEED SENSOR: DISCONNECTION (LEFT REAR) 1046
FAILURE CODE [DLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTION 1047
FAILURE CODE [DLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISAGREEMENT OF REVOLUTION SPEED SIGNAL 1049
FAILURE CODE [DLT4KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTION 1051
FAILURE CODE [DLT4MA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTION 1053
FAILURE CODE [DV00KB] BUZZER OUTPUT: SHORT CIRCUIT 1055
FAILURE CODE [DW2AKA] MAIN PRESSURE VARIABLE VALVE OUTPUT: DISCONNECTION 1057
FAILURE CODE [DW2AKB] MAIN PRESSURE VARIABLE VALVE OUTPUT CIRCUIT: GROUND FAULT 1059
FAILURE CODE [DW2AKY] MAIN PRESSURE VARIABLE VALVE OUTPUT CIRCUIT: HOT SHORT 1061
FAILURE CODE [DW2AL1] MAIN PRESSURE VARIABLE VALVE: DEFECTIVE RESET 1062
FAILURE CODE [DW2ALH] MAIN PRESSURE VARIABLE VALVE: MALFUNCTION 1064
FAILURE CODE [DW2BKA] MAIN OIL LEVEL SELECTOR VALVE OUTPUT: DISCONNECTION 1065
FAILURE CODE [DW2BKB] MAIN OIL LEVEL SELECTOR VALVE OUTPUT CIRCUIT: GROUND FAULT 1066
FAILURE CODE [DW2BKY] MAIN OIL LEVEL SELECTOR VALVE OUTPUT CIRCUIT: HOT SHORT 1068
FAILURE CODE [DW2BL1] MAIN OIL LEVEL SELECTOR VALVE: DEFECTIVE RESET 1069
FAILURE CODE [DW2BLH] MAIN OIL LEVEL SELECTOR VALVE: MALFUNCTION 1071
FAILURE CODE [DW2CKA] TRANSMISSION LUBRICATION VARIABLE VALVE OUTPUT: DISCONNECTION 1072
FAILURE CODE [DW2CKB] TRANSMISSION LUBRICATION VARIABLE VALVE OUTPUT CIRCUIT: GROUND FAULT 1073
FAILURE CODE [DW2CKY] TRANSMISSION LUBRICATION VARIABLE VALVE OUTPUT CIRCUIT: HOT SHORT 1075
FAILURE CODE [DW2CL1] TRANSMISSION LUBRICATION VARIABLE VALVE: DEFECTIVE RESET 1076
FAILURE CODE [DW2CLH] TRANSMISSION LUBRICATION VARIABLE VALVE: MALFUNCTION 1078
FAILURE CODE [DW35KZ] FAILURE IN OUTPUT SYSTEM OF AUTO SUSPENSION SOLENOID 1: DISCONNECTION OR SHORT CIRCUIT 1079
FAILURE CODE [DW36KZ] FAILURE IN OUTPUT SYSTEM OF AUTO SUSPENSION SOLENOID 2: DISCONNECTION OR SHORT CIRCUIT 1081
FAILURE CODE [DW71KZ] EXHAUST BRAKE OUTPUT SYSTEM TROUBLE (DISCONECTION/GROUND FAULT/HOT SHORT) 1083
FAILURE CODE [DW72KZ] KICK-OUT SOLENOID OUTPUT SYSTEM TROUBLE: DISCONNECTION OR SHORT CIRCUIT 1085
FAILURE CODE [DW73KZ] FAILURE IN HOIST SELECT VALVE OUTPUT SYSTEM: DISCONNECTION OR SHORT CIRCUIT 1087
FAILURE CODE [DW78KZ] BRAKE COOLING VALVE (BCV) (REAR WHEEL) OUTPUT SYSTEM TROUBLE: DISCONNECTION OR SHORT CIRCUIT 1089
FAILURE CODE [DWNBK4] ASR SHUT-OFF VALVE: TROUBLE (VALVE KEEPS OPERATING) 1091
FAILURE CODE [DWNBKA] ASR SHUT-OFF VALVE OUTPUT CIRCUIT: DISCONNECTION 1093
FAILURE CODE [DWNBKB] ASR SHUT-OFF VALVE OUTPUT CIRCUIT: GROUND FAULT 1095
FAILURE CODE [DWNBKY] ASR SHUT-OFF VALVE OUTPUT CIRCUIT: SHORT CIRCUIT 1097
FAILURE CODE [DWNBMA] ASR SHUT-OFF VALVE: TROUBLE (VALVE DOES NOT OPERATE) 1097
TROUBLESHOOTING BY FAILURE CODE, PART 9 1099
FAILURE CODE [DX11K4] REAR BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE: OUT OF CONTROL 1101
FAILURE CODE [DX11KA] REAR BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE OUTPUT CIRCUIT:DISCONNECTION 1103
FAILURE CODE [DX11KB] REAR BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE: SHORT CIRCUIT 1104
FAILURE CODE [DX11KY] REAR BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE: SHORT CIRCUIT TO POWER SOURCE LINE 1105
FAILURE CODE [DX11MA] REAR BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE: ALFUNCTION 1106
FAILURE CODE [DX12K4] FRONT BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE: OUT OF CONTROL 1108
FAILURE CODE [DX12KA] FRONT BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE OUTPUT CIRCUIT:DISCONNECTION 1110
FAILURE CODE [DX12KB] FRONT BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE: SHORT CIRCUIT 1111
FAILURE CODE [DX12KY] FRONT BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE: SHORT CIRCUIT TO POWER SOURCE LINE 1112
FAILURE CODE [DX12MA] FRONT BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE: ALFUNCTION 1113
FAILURE CODE [DX13KA] OUTPUT CIRCUIT OF HOIST EPC VALVE: DISCONNECTION 1115
FAILURE CODE [DX13KB] OUTPUT CIRCUIT OF HOIST EPC VALVE: SHORT CIRCUIT 1117
FAILURE CODE [DX13KY] OUTPUT CIRCUIT OF HOIST EPC VALVE: SHORT CIRCUIT WITH POWER SOURCE LINE 1119
FAILURE CODE [DX17K4] ASR PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE (RIGHT): TROUBLE (VALVE KEEPS OPERATING) 1121
FAILURE CODE [DX17KA] ASR PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE (RIGHT) OUTPUT CIRCUIT: DISCONNECTION 1123
FAILURE CODE [DX17KB] ASR PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE (RIGHT) OUTPUT CIRCUIT: GROUND FAULT 1124
FAILURE CODE [DX17KY] ASR PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE (RIGHT) OUTPUT CIRCUIT:SHORT CIRCUIT 1126
FAILURE CODE [DX17MA] ASR PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE (RIGHT): TROUBLE (VALVE DOES NOT OPERATE) 1126
FAILURE CODE [DX18K4] ASR PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE (LEFT): TROUBLE (VALVE KEEPS OPERATING) 1127
FAILURE CODE [DX18KA] ASR PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE (LEFT) OUTPUT CIRCUIT:DISCONNECTION 1129
FAILURE CODE [DX18KB] ASR PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE (LEFT) OUTPUT CIRCUIT: GROUND FAULT 1130
FAILURE CODE [DX18KY] ASR PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE (LEFT) OUTPUT CIRCUIT: SHORT CIRCUIT 1132
FAILURE CODE [DX18MA] ASR PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE (LEFT): TROUBLE (VALVE DOES NOT OPERATE) 1132
TROUBLESHOOTING BY FAILURE CODE, PART 10 1134
FAILURE CODE [DXH1KA] LOCKUP CLUTCH SOLENOID OUTPUT CIRCUIT: DISCONNECTION 1136
FAILURE CODE [DXH1KB] LOCK-UP CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT 1137
FAILURE CODE [DXH1KY] LOCKUP CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT TO POWER SOURCE LINE 1138
FAILURE CODE [DXH2KA] HI CLUTCH SOLENOID OUTPUT CIRCUIT: DISCONNECTION 1139
FAILURE CODE [DXH2KB] HI CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT 1141
FAILURE CODE [DXH2KY] HI CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT TO POWER SOURCE LINE 1143
FAILURE CODE [DXH3KA] LO CLUTCH SOLENOID OUTPUT CIRCUIT: DISCONNECTION 1146
FAILURE CODE [DXH3KB] LO CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT 1148
FAILURE CODE [DXH3KY] LO CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT IN POWER SOURCE LINE 1150
FAILURE CODE [DXH4KA] 1ST CLUTCH SOLENOID OUTPUT CIRCUIT: DISCONNECTION 1153
FAILURE CODE [DXH4KB] 1ST CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT 1155
FAILURE CODE [DXH4KY] 1ST CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT TO POWER SOURCE LINE 1157
FAILURE CODE [DXH5KA] 2ND CLUTCH SOLENOID OUTPUT CIRCUIT: DISCONNECTION 1160
FAILURE CODE [DXH5KB] 2ND CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT 1162
FAILURE CODE [DXH5KY] 2ND CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT IN POWER SOURCE 1164
FAILURE CODE [DXH6KA] 3RD CLUTCH SOLENOID OUTPUT CIRCUIT: DISCONNECTION 1167
FAILURE CODE [DXH6KB] 3RD CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT 1169
FAILURE CODE [DXH6KY] 3RD CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT TO POWER SOURCE LINE 1171
FAILURE CODE [DXH7KA] R CLUTCH SOLENOID OUTPUT CIRCUIT: DISCONNECTION 1174
FAILURE CODE [DXH7KB] R CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT 1176
FAILURE CODE [DXH7KY] R CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT TO POWER SOURCE LINE 1178
FAILURE CODE [DXHHKA] 4TH CLUTCH SOLENOID OUTPUT CIRCUIT: DISCONNECTION 1179
FAILURE CODE [DXHHKB] 4TH CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT 1181
FAILURE CODE [DXHHKY] 4TH CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT TO POWER SOURCE LINE 1183
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 1187
BEFORE TROUBLESHOOTING OF ELECTRIC SYSTEM 1189
CONTENTS OF TROUBLESHOOTING TABLE 1190
E-1 ENGINE DOES NOT START 1191
E-2 AUTOMATIC PREHEATING DOES NOT OPERATE 1194
E-3 MACHINE MONITOR DOES NOT DISPLAY ALL, WHEN STARTING SWITCH IS TURNED ON 1197
E-4 MACHINE MONITOR DOES NOT OPERATE WHEN STARTING SWITCH IS OFF 1199
E-5 ALARM BUZZER DOES NOT SOUND 1201
E-6 GAUGES OF MACHINE MONITOR, CAUTION LAMPS OR CHARACTER DISPLAY SECTION DO NOT DISPLAY PROPERLY 1203
E-7 A SELECTION OF THE DISPLAY IN CHARACTER DISPLAY SECTION CANNOT BE CHANGED 1204
E-8 POWER MODE SELECTING FUNCTION DOES NOT OPERATE PROPERLY 1207
E-9 AISS FUNCTION DOES NOT OPERATE PROPERLY 1208
E-10 SEAT BELT CAUTION LAMP DOES NOT DISPLAY PROPERLY 1209
E-11 TURN SIGNAL LAMP OR TURNING LAMP (HAZARD LAMP) DO NOT WORK PROPERLY 1210
E-12 NIGHT ILLUMINATION (LIGHTING) DOES NOT WORK PROPERLY 1213
E-13 EMERGENCY STEERING DOES NOT OPERATE 1225
E-14 HOIST LEVER DOES NOT OPERATE NORMALLY 1230
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) 1233
CONTENTS OF TROUBLESHOOTING TABLE 1235
H-1 MACHINE DOES NOT START 1236
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (HUNTING) 1238
H-3 LOCKUP CANNOT BE CANCELLED 1238
H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING EXCESSIVE 1239
H-5 TRANSMISSION DOES NOT SHIFT UP 1240
H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING 1242
H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR 1245
H-8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH 1247
H-9 TORQUE CONVERTER OIL PRESSURE IS LOW 1248
H-10 FRONT BRAKE IS INEFFECTIVE 1249
H-11 REAR BRAKE IS INEFFECTIVE 1250
H-12 STEERING WHEEL IS HEAVY 1251
H-13 STEERING WHEEL DOES NOT WORK 1252
H-14 STEERING WHEEL VIBRATES 1253
H-15 DUMP BODY LIFTING SPEED IS SLOW 1254
H-16 DUMP BODY DOES NOT WORK 1255
H-17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY 1256
TROUBLESHOOTING OF ENGINE (S-MODE) 1258
METHOD OF USING TROUBLESHOOTING CHARTS 1260
S-1 STARTING PERFORMANCE IS POOR 1263
S-2 ENGINE DOES NOT START 1264
S-3 ENGINE DOES NOT PICK UP SMOOTHLY 1267
S-4 ENGINE STOPS DURING OPERATIONS 1268
S-5 ENGINE DOES NOT ROTATE SMOOTHLY 1269
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER) 1270
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) 1272
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) 1273
S-9 OIL BECOMES CONTAMINATED QUICKLY 1274
S-10 FUEL CONSUMPTION IS EXCESSIVE 1275
S-11 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 1276
S-12 OIL PRESSURE DROPS 1277
S-13 OIL LEVEL RISES (ENTRY OF COOLANT OR FUEL) 1278
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 1279
S-15 ABNORMAL NOISE IS MADE 1280
S-16 VIBRATION IS EXCESSIVE 1281
50 DISASSEMBLY AND ASSEMBLY 0
GENERAL INFORMATION ON DISASSEMBLY AND ASSEMBLY 1283
HOW TO READ THIS MANUAL 1284
LIST OF ADHESIVES 1286
SPECIAL TOOL LIST 1289
SKETCHES OF SPECIAL TOOLS 1290
ENGINE AND COOLING SYSTEM 1292
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP 1293
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY 1295
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY 1303
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY 1310
POWER TRAIN, PART 1 1315
REMOVAL AND INSTALLATION OF FRONT DRIVE SHAFT 1316
REMOVAL AND INSTALLATION OF TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 1318
DISCONNECTION AND CONNECTION OF TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 1321
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER AND PTO ASSEMBLIES 1328
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION ASSEMBLY 1340
POWER TRAIN, PART 2 1373
DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY 1374
DISASSEMBLY AND ASSEMBLY OF FRONT BRAKE ASSEMBLY 1387
DISASSEMBLY AND ASSEMBLY OF REAR BRAKE ASSEMBLY 1394
90 DIAGRAMS AND DRAWINGS 0
HYDRAULIC DIAGRAMS AND DRAWINGS 1407
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 1409
STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM 1411
BRAKE HYDRAULIC CIRCUIT DIAGRAM 1413
BRAKE HYDRAULIC CIRCUIT DIAGRAM (ASR SPECIFICATION) 1415
BRAKE HYDRAULIC CIRCUIT DIAGRAM (ABS SPECIFICATION) 1417
BRAKE HYDRAULIC CIRCUIT DIAGRAM (ASR AND ABS SPECIFICATION) 1419
ELECTRICAL DIAGRAMS AND DRAWINGS 1423
ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (1/3) 1425
ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (2/3) 1426
ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (3/3) 1427
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (1/3) 1428
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (2/3) 1429
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (3/3) 1430
ELECTRICAL CIRCUIT DIAGRAM FOR VHMS 1431
ELECTRICAL CIRCUIT DIAGRAM FOR ABS (OUTSIDE CAB) 1432
ELECTRICAL CIRCUIT DIAGRAM FOR ABS (INSIDE CAB) 1433
ELECTRICAL CIRCUIT DIAGRAM FOR ASR 1434
CONNECTORS TABLE AND ARRANGEMENT DRAWING 1435
DESCRIPTION:
Komatsu HD785-7 Dump Truck Shop Manual SEN01274-04-N1-00 – PDF DOWNLOAD
SERIAL NUMBERS N10001 – N10560
How to read the shop manual
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. 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 S mode of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
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)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
S.V 26/12/24
