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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 โ 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 DOWNLOADย
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 DOWNLOADย
SERIAL NUMBERS N10001 โ N10560
00 INDEX AND FOREWORDย ย 0
INDEXย ย 2
COMPOSITION OF SHOP MANUALย 3
TABLE OF CONTENTSย ย 5
FOREWORD AND GENERAL INFORMATIONย ย 20
SAFETY NOTICEย 21
HOW TO READ THE SHOP MANUALย 26
EXPLANATION OF TERMS FOR MAINTENANCE STANDARDย 28
HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTย 30
HOW TO READ ELECTRIC WIRE CODEย ย 42
PRECAUTIONS WHEN CARRYING OUT OPERATIONย 45
METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLERย 48
STANDARD TIGHTENING TORQUE TABLEย ย 51
CONVERSION TABLEย ย 55
01 SPECIFICATIONย 0
SPECIFICATION AND TECHNICAL DATAย ย 62
SPECIFICATION DRAWINGย 63
SPECIFICATIONSย ย 64
WEIGHT TABLEย ย 67
FUEL, COOLANT AND LUBRICANTSย ย 68
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARDย ย 0
ENGINE AND COOLING SYSTEMย 72
RADIATOR, BRAKE, TORQUE CONVERTER OIL COOLER, AFTERCOOLER, STEERING, HOIST OIL COOLERย 73
POWER TRAIN, PART 1ย 78
POWER TRAIN SKELETONย ย 79
OUTPUT SHAFTย ย 81
DRIVE SHAFTย 83
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPINGย ย 85
BRAKE COOLING OIL CONTROL VALVE (BCV)ย 87
TORQUE CONVERTERย ย 88
TORQUE CONVERTER VALVEย ย 96
TRANSMISSIONย ย 99
TRANSMISSION CONTROL VALVEย 127
ECMVย 129
LUBRICATING OIL AMOUNT SELECTOR VALVEย ย 136
POWER TRAIN, PART 2ย ย 140
AXLEย 141
DIFFERENTIALย 143
FINAL DRIVEย ย 144
WHEELSย 145
STEERING SYSTEMย ย 148
STEERING COLUMNย ย 149
STEERING LINKAGEย 150
BRAKE SYSTEMย 154
BRAKE PIPINGย 155
BRAKE VALVEย ย 157
SECONDARY BRAKE VALVEย ย 160
ACCUMULATOR CHARGE VALVEย 161
ACCUMULATORย ย 165
SLACK ADJUSTERย 166
BRAKE, PARKING BRAKEย 170
PARKING BRAKE SOLENOIDย 176
SOLENOID VALVEย 177
EXHAUST BRAKEย ย 179
UNDERCARRIAGE AND FRAMEย ย 182
SUSPENSIONย 183
SUSPENSION CYLINDERย ย 185
REAR AXLE SUPPORTย ย 193
HYDRAULIC SYSTEMย 196
STEERING AND HOIST HYDRAULIC PIPINGย ย 197
STEERING, HOIST FILTER (HIGH PRESSURE CIRCUIT)ย 199
DUMP BODY CONTROLย ย 201
HYDRAULIC TANKย 203
STEERING VALVEย 204
CROSSOVER RELIEF VALVEย 208
STEERING CYLINDERย ย 209
STEERING CONTROL VALVEย 210
HOIST VALVEย ย 219
DUMP CONTROL VALVE (EPC VALVE)ย 225
HOIST CYLINDERย 226
HYDRAULIC PUMPย 227
CAB AND ITS ATTACHMENTSย ย 232
ROPS CABย 233
AIR CONDITIONERย ย 234
REAR VIEW MONITORย ย 243
CONTROLLER RELATEDย 246
ELECTRICAL SYSTEM, PART 1ย ย 248
MACHINE MONITOR SYSTEMย 249
ELECTRICAL SYSTEM, PART 2ย ย 274
AUTOMATIC SHIFT CONTROL SYSTEMย 275
AUTOMATIC EMERGENCY STEERING SYSTEMย ย 293
AUTOMATIC SUSPENSION SYSTEMย ย 297
RETARDER CONTROL SYSTEMย ย 300
DUMP CONTROL LEVERย 313
ELECTRICAL SYSTEM, PART 3ย ย 318
VHMS CONTROLLER RELATEDย ย 319
ABS/ASR SYSTEMย 345
ALTITUDE SETTING FUNCTIONย ย 363
ELECTRICAL SYSTEM, PART 4ย ย 368
SENSORS, SWITCHESย ย 369
20 STANDARD VALUE TABLEย ย 0
STANDARD SERVICE VALUE TABLEย 386
STANDARD VALUE TABLE FOR ENGINEย ย 387
STANDARD VALUE TABLE FOR MACHINEย 389
30 TESTING AND ADJUSTINGย 0
TESTING AND ADJUSTING, PART 1ย ย 400
TESTING AND ADJUSTING TOOLS LISTย 402
TESTING ENGINE SPEEDย 408
TESTING AIR SUPPLY PRESSURE (BOOST PRESSURE)ย 409
TESTING EXHAUST TEMPERATUREย ย 411
TESTING EXHAUST GAS COLORย ย 413
ADJUSTMENT OF VALVE CLEARANCEย ย 415
TESTING COMPRESSION PRESSUREย 417
TESTING BLOW-BY PRESSUREย 419
TESTING ENGINE OIL PRESSUREย ย 420
HANDLING OF FUEL SYSTEM DEVICESย ย 421
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEMย 421
TESTING FUEL PRESSUREย ย 422
REDUCED CYLINDER MODE OPERATIONย ย 423
NO-INJECTION CRANKINGย ย 423
TESTING LEAKAGE-FROM PRESSURE LIMITER AND RETURN RATE FROM INJECTOR 424
BLEEDING AIR FROM FUEL CIRCUIT (STANDARD SPEC )ย ย 427
BLEEDING AIR FROM FUEL CIRCUIT (EXTRA LOW-GRADE FUEL SPEC ) 429
TESTING THE FUEL CIRCUIT FOR LEAKAGEย 431
REPLACEMENT AND ADJUSTMENT OF FAN BELTย 432
TESTING AND ADJUSTING ALTERNATOR BELT TENSIONย ย 433
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT 434
TESTING AND ADJUSTING, PART 2ย ย 436
TESTING TORQUE CONVERTER STALL SPEEDย 438
TESTING POWER TRAIN OIL PRESSUREย 439
ADJUSTING TRANSMISSION SPEED SENSORย ย 447
TESTING AND ADJUSTING BRAKE OIL PRESSUREย 448
TESTING OF ACCUMULATOR NITROGEN GAS PRESSURE AND PROCEDURE FOR CHARGING ACCUMULATOR WITH NITROGEN GAS 451
TESTING BRAKE PERFORMANCEย ย 454
BLEEDING AIR FROM BRAKE CIRCUITย ย 456
BLEEDING AIR FROM ASR CIRCUIT (IF EQUIPPED)ย ย 458
TESTING WEAR OF FRONT BRAKE DISCย 459
TESTING WEAR OF REAR BRAKE DISCย ย 460
METHOD OF RELEASING PARKING BRAKE IN AN EMERGENCYย ย 461
TESTING AND ADJUSTING FRONT SUSPENSION CYLINDERย ย 462
TESTING AND ADJUSTING REAR SUSPENSION CYLINDERย 466
TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION)ย 470
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING, HOIST CIRCUIT 471
TESTING AND ADJUSTING OIL PRESSURE IN DUMP EPC CIRCUITย 474
AIR BLEEDING FROM STEERING CYLINDERย ย 475
PROCEDURE FOR RAISING DUMP BODY IN EMERGENCYย 476
ADJUSTING BODY POSITIONER SENSORย 477
HANDLING OF VOLTAGE CIRCUIT OF ENGINE CONTROLLERย 479
ADJUSTING TRANSMISSION CONTROLLERย ย 479
METHOD FOR EMERGENCY ESCAPE AT ELECTRICAL SYSTEM FAILUREย 480
TESTING AND ADJUSTING, PART 3ย ย 485
SETTING AND ADJUSTING OF DEVICESย 486
SPECIAL FUNCTIONS OF MACHINE MONITOR (EMMS)ย ย 498
TESTING AND ADJUSTING, PART 4ย ย 522
SPECIAL FUNCTIONS OF MACHINE MONITOR (EMMS)ย ย 523
TESTING AND ADJUSTING, PART 5ย ย 566
VHMS CONTROLLER INITIAL SETTING PROCEDUREย ย 567
PRECAUTIONS FOR REPLACING VHMS CONTROLLERย ย 588
PM CLINIC CHECK SHEETย ย 594
INITIAL SETTING OF PAYLOAD METERย 598
SETTING OF PAYLOAD METER BUILT IN VHMSย 599
40 TROUBLESHOOTINGย 0
FAILURE CODE TABLE AND FUSE LOCATIONSย ย 608
FAILURE CODES TABLEย ย 609
FUSE LOCATIONSย 623
GENERAL INFORMATION ON TROUBLESHOOTINGย 629
POINTS TO REMEMBER WHEN TROUBLESHOOTINGย ย 630
SEQUENCE OF EVENTS IN TROUBLESHOOTINGย ย 631
CHECK BEFORE TROUBLESHOOTINGย 632
CLASSIFICATION AND PROCEDURES FOR TROUBLESHOOTINGย ย 633
CONTENTS OF TROUBLESHOOTING TABLEย ย 634
CONNECTION TABLE FOR CONNECTOR PIN NUMBERSย 636
T-ADAPTER BOX AND T-ADAPTER TABLEย ย 665
TROUBLESHOOTING BY FAILURE CODE, PART 1ย ย 669
FAILURE CODE [1500L0] DUAL ENGAGEMENTย ย 671
FAILURE CODE [15B0NX] TRANSMISSION OIL FILTER: CLOGGING 672
FAILURE CODE [15F0KM] Rโข F SHIFTING ABUSE 1: MISTAKE IN OPERATION 674
FAILURE CODE [15F0MB] Rโข F SHIFTING ABUSE 2: MISTAKE IN OPERATION 674
FAILURE CODE [15F7KM] FORWARD CLUTCH DISK ABUSE: MISTAKE IN OPERATION OR SETTINGย 675
FAILURE CODE [15G0MW] R CLUTCH: SLIPPINGย 676
FAILURE CODE [15G7KM] REVERSE CLUTCH DISK ABUSE: MISTAKE IN OPERATION OR SETTINGย 678
FAILURE CODE [15H0MW] HI CLUTCH: SLIPPINGย ย 679
FAILURE CODE [15J0MW] LO CLUTCH: SLIPPINGย ย 681
FAILURE CODE [15K0MW] 1ST CLUTCH: SLIPPINGย 683
FAILURE CODE [15L0MW] 2ND CLUTCH: SLIPPINGย 685
FAILURE CODE [15M0MW] 3RD CLUTCH: SLIPPINGย 687
FAILURE CODE [15N0MW] 4TH CLUTCH: SLIPPINGย 689
FAILURE CODE [15SBL1] R CLUTCH SOLENOID: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFFย 691
FAILURE CODE [15SBMA] R CLUTCH SOLENOID: MALFUNCTIONย 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 OFFย 705
FAILURE CODE [15SEMA] 1ST CLUTCH SOLENOID: MALFUNCTIONย 708
TROUBLESHOOTING BY FAILURE CODE, PART 2ย ย 711
FAILURE CODE [15SFL1] 2ND CLUTCH SOLENOID: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFFย 713
FAILURE CODE [15SFMA] 2ND CLUTCH SOLENOID: MALFUNCTIONย 716
FAILURE CODE [15SGL1] 3RD CLUTCH SOLENOID: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFFย 718
FAILURE CODE [15SGMA] 3RD CLUTCH SOLENOID: MALFUNCTIONย 721
FAILURE CODE [15SHL1] 4TH CLUTCH SOLENOID: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFFย 723
FAILURE CODE [15SHMA] 4TH CLUTCH SOLENOID: MALFUNCTIONย 726
FAILURE CODE [15SJMA] LOCKUP CLUTCH SOLENOID: MALFUNCTION 728
FAILURE CODE [2F00KM] PARKING BRAKE: MISTAKE IN OPERATION OR SETTINGย 729
FAILURE CODE [2G42ZG] ACCUMULATOR: OIL PRESSURE REDUCTION (FRONT) 732
FAILURE CODE [2G43ZG] ACCUMULATOR: OIL PRESSURE REDUCTION (REAR)ย 732
FAILURE CODE [989A00] ENGINE OVER RUN PREVENTION COMMAND SIGNAL: OPERATINGย 733
FAILURE CODE [989D00] REAR SECTION TIPPING OVER ALARM: ALARM IS ACTIVATED 733
FAILURE CODE [A570NX] ENGINE OIL FILTER: CLOGGINGย ย 734
FAILURE CODE [AA10NX] AIR CLEANER ELEMENT: CLOGGINGย ย 736
FAILURE CODE [AB00MA] ALTERNATOR: MALFUNCTIONย ย 738
FAILURE CODE [B@BAZG] ABNORMAL LOWERING OF ENGINE OIL PRESSURE: LOWERING OF OIL PRESSUREย 740
FAILURE CODE [B@BAZK] ENGINE OIL: LEVEL TOO LOWย ย 742
FAILURE CODE [B@BCNS] ENGINE: OVERHEATย 744
FAILURE CODE [B@BCZK] LOWERING OF RADIATOR COOLANT: LOWERING OF LEVEL 746
FAILURE CODE [B@BFZK] LOWERING OF FUEL LEVELย 748
FAILURE CODE [B@C6NS] BRAKE COOLING OIL: OVERHEATING (FRONT)ย 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 LEVELย 754
FAILURE CODE [B@JANS] STEERING OIL: OVERHEATย 755
TROUBLESHOOTING BY FAILURE CODE, PART 3ย ย 757
FAILURE CODE [CA111] ENGINE CONTROLLER (LEFT BANK): INTERNAL ABNORMALITYย 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 SIGNALย 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 ERRORย ย 768
FAILURE CODE [CA132] THROTTLE SENSOR LOW ERRORย 770
FAILURE CODE [CA135] OIL PRESSURE SENSOR TOO HIGH (AT LEFT BANK ONLY): EXCESSIVELY HIGH VOLTAGE DETECTEDย 771
FAILURE CODE [CA141] OIL PRESSURE SENSOR TOO LOW (AT LEFT BANK ONLY): EXCESSIVELY LOW VOLTAGE DETECTEDย 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 DETECTEDย 778
FAILURE CODE [CA154] CHARGE TEMPERATURE SENSOR TOO LOW (AT LEFT BANK ONLY): EXCESSIVELY LOW VOLTAGE DETECTEDย 780
FAILURE CODE [CA187] SENSOR POWER SUPPLY (2) ABNORMALLY LOW LEVEL (LEFT BANK): LOW VOLTAGE DETECTIONย 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 DETECTEDย 786
FAILURE CODE [CA222] ATMOSPHERIC PRESSURE SENSOR TOO LOW (AT LEFT BANK ONLY): EXCESSIVELY LOW VOLTAGE DETECTEDย 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 SPEEDย 793
FAILURE CODE [CA238] ABNORMAL POWER SOURCE FOR NE SPEED SENSOR (AT LEFT BANK ONLY): EXCESSIVELY LOW VOLTAGE DETECTEDย 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 DETECTEDย 800
FAILURE CODE [CA265] FUEL TEMPERATURE SENSOR ABNORMALLY LOW LEVEL (LEFT BANK): LOW VOLTAGE DETECTIONย 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 CIRCUITย 803
FAILURE CODE [CB271] PCV1 SHORT CIRCUIT (RIGHT BANK): SHORT CIRCUIT 804
FAILURE CODE [CA272] PCV1 DISCONNECTION (LEFT BANK): DISCONNECTIONย 805
FAILURE CODE [CB272] PCV1 DISCONNECTION (RIGHT BANK): DISCONNECTION 806
FAILURE CODE [CA273] PCV2 SHORT CIRCUIT (LEFT BANK): SHORT CIRCUITย 807
FAILURE CODE [CB273] PCV2 SHORT CIRCUIT (RIGHT BANK): SHORT CIRCUIT 808
FAILURE CODE [CA274] PCV2 DISCONNECTION (LEFT BANK): DISCONNECTIONย 809
FAILURE CODE [CB274] PCV2 DISCONNECTION (RIGHT BANK): DISCONNECTION 810
TROUBLESHOOTING BY FAILURE CODE, PART 4ย ย 812
FAILURE CODE [CA322] INJECTOR NOย 1 (L/B NO 1) SYSTEM DISCONNECTION OR SHORT CIRCUIT (AT LEFT BANK): DISCONNECTION, SHORT CIRCUIT 814
FAILURE CODE [CA323] INJECTOR NOย 5 (L/B NO 5) SYSTEM DISCONNECTION OR SHORT CIRCUIT (AT LEFT BANK): DISCONNECTION, SHORT CIRCUIT 816
FAILURE CODE [CA324] INJECTOR NOย 3 (L/B NO 3) SYSTEM DISCONNECTION OR SHORT CIRCUIT (AT LEFT BANK): DISCONNECTION, SHORT CIRCUIT 818
FAILURE CODE [CA325] INJECTOR NOย 6 (L/B NO 6) SYSTEM DISCONNECTION OR SHORT CIRCUIT (AT LEFT BANK): DISCONNECTION, SHORT CIRCUIT 820
FAILURE CODE [CA331] INJECTOR NOย 2 (L/B NO 2) SYSTEM DISCONNECTION OR SHORT CIRCUIT (AT LEFT BANK): DISCONNECTION, SHORT CIRCUIT 822
FAILURE CODE [CA332] INJECTOR NOย 4 (L/B NO 4) SYSTEM DISCONNECTION OR SHORT CIRCUIT (AT LEFT BANK):DISCONNECTION, SHORT CIRCUITย 824
FAILURE CODE [CA342] ENGINE CONTROLLER DATA MISMATCH (LEFT BANK): MISMATCHย 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 DETECTIONย 832
FAILURE CODE [CB386] SENSOR POWER SUPPLY (1) ABNORMALLY HIGH LEVEL (RIGHT BANK): HIGH VOLTAGE DETECTION 834
FAILURE CODE [CA431] TROUBLE IN IDLE VALIDATION SWITCHย 836
FAILURE CODE [CA432] IDLE VALIDATION ACTION ERRORย ย 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 DETECTIONย 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 DETECTIONย 840
FAILURE CODE [CA449] COMMON RAIL ABNORMALLY HIGH PRESSURE (2) (LEFT BANK): ABNORMALLY HIGH PRESSURE OCCURRENCEย 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 DETECTEDย 847
FAILURE CODE [CB553] COMMON RAIL PRESSURE TOO HIGH (1) (AT RIGHT BANK): EXCESSIVELY HIGH PRESSURE DETECTEDย 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 ERRORย 849
FAILURE CODE [CA559] LOSS OF PRESSURE FEED FROM SUPPLY PUMP (1) (AT LEFT BANK): LOSS OF PRESSURE FEED DETECTEDย 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 SIGNALย 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 DETECTIONย 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 PHASEย 865
TROUBLESHOOTING BY FAILURE CODE, PART 5ย ย 867
FAILURE CODE [CA757] LOSS OF ALL ENGINE CONTROLLER DATA (AT LEFT BANK): LOSS OF ALL DATAย 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 ERRORย 876
FAILURE CODE [CA1257] MULTICONTROLLER DISTINCTION WIRING HARNESS KEY ERROR (LEFT BANK):DISTINCTION ERRORย 877
FAILURE CODE [CB1257] MULTICONTROLLER DISTINCTION WIRING HARNESS KEY ERROR (RIGHT BANK): DISTINCTION ERRORย 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 CIRCUITย 883
FAILURE CODE [CB1552] INJECTOR #11 (R/B #5) SYSTEM DISCONNECTION/SHORT CIRCUIT (RIGHT BANK): DISCONNECTION/SHORT CIRCUITย 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 CIRCUITย 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 ERRORย 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 DETECTEDย 896
FAILURE CODE [CA2555] INTAKE HEATER RELAY VOLTAGE LOW ERROR (AT LEFT BANK)ย 897
FAILURE CODE [CA2556] INTAKE HEATER RELAY VOLTAGE HIGH ERROR (AT LEFT BANK) 898
TROUBLESHOOTING BY FAILURE CODE, PART 6ย ย 901
FAILURE CODE [D19HKB] STOP LAMP RELAY OUTPUT SYSTEM: SHORT CIRCUITย 903
FAILURE CODE [DAF9KM] WRONG CONNECTION OF CONNECTORย ย 904
FAILURE CODE [DAFRKR] CAN COMMUNICATION ERROR (MACHINE MONITOR): COMMUNICATION ERRORย 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 SELECTIONย 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 TROUBLEย 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)ย 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)ย 934
FAILURE CODE [DBCRKR] ABNORMALITY IN CAN COMMUNICATION (ABS)ย 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: DISCONNECTIONย 938
FAILURE CODE [DDD8KB] ARSC SYSTEM SWITCH SYSTEM: SHORT CIRCUITย 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: DISCONNECTIONย 946
FAILURE CODE [DDDAKB] ASR SYSTEM SWITCH: SHORT CIRCUITย 948
FAILURE CODE [DDP6L4] SERVICE BRAKE PRESSURE SWITCH TROUBLE (REAR)ย 950
FAILURE CODE [DDTHKA] HI CLUTCH FILL SWITCH: DISCONNECTIONย 952
FAILURE CODE [DDTJKA] LO CLUTCH FILL SWITCH: DISCONNECTIONย 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 RANGEย 972
FAILURE CODE [DGR2KB] TROUBLE IN RETARDER OIL TEMPERATURE SENSOR (REAR WHEEL) SYSTEM (DISCONNECTION AND SHORT CIRCUIT)ย 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)ย 980
FAILURE CODE [DGR6KX] STEERING OIL TEMPERATURE SENSOR: INPUT SIGNAL OUT OF RANGEย 982
FAILURE CODE [DGT1KX] TORQUE CONVERTER OIL TEMPERATURE SENSOR: OUT OF INPUT SIGNAL RANGEย 984
TROUBLESHOOTING BY FAILURE CODE, PART 7ย ย 987
FAILURE CODE [DHP4KY] SUSPENSION PRESSURE SENSOR SYSTEM: SHORT CIRCUIT (RIGHT FRONT)ย 989
FAILURE CODE [DHP4KZ] SUSPENSION PRESSURE SENSOR SYSTEM: DISCONNECTION OR GROUND FAULT (RIGHT FRONT)ย 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)ย 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)ย 999
FAILURE CODE [DHP7KX] FAILURE IN SUSPENSION PRESSURE SENSOR SYSTEM TROUBLE: OUT OF INPUT SIGNAL RANGE (LEFT REAR)ย 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 RANGEย 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 RANGEย 1009
FAILURE CODE [DJF1KA] FUEL LEVEL SENSOR: DISCONNECTION 1011
FAILURE CODE [DK30KX] STEERING ANGLE POTENTIOMETER: TROUBLE (DISCONNECTION)ย 1012
FAILURE CODE [DK51L5] TROUBLE IN RETARDER LEVER POTENTIOMETER AND RVSย 1013
FAILURE CODE [DK52KX] FAILURE IN HOIST LEVER POTENTIOMETER 1: OUT OF INPUT SIGNAL RANGEย 1016
FAILURE CODE [DK53L8] FAILURE IN HOIST LEVER POTENTIOMETER 2: DISAGREEMENT OF ANALOG SIGNALย 1018
FAILURE CODE [DK54KX] BODY POSITIONER SENSOR: OUT OF INPUT SIGNAL RANGEย 1019
FAILURE CODE [DKD0L6] FAILURE IN STEERING ANGLE SPEED SENSOR 1021
FAILURE CODE [DKH0KX] PITCH ANGLE SENSOR: OUT OF INPUT SIGNAL RANGEย 1023
FAILURE CODE [DKH1KX] PITCH ANGLE SENSOR: ABNORMALITYย 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: DISCONNECTIONย 1030
FAILURE CODE [DLF2LC] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: DISAGREEMENT OF REVOLUTION SPEED SIGNALย 1032
TROUBLESHOOTING BY FAILURE CODE, PART 8ย 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)ย 1042
FAILURE CODE [DLF9L3] WHEEL SPEED SENSOR: TROUBLE (LEFT REAR)ย 1044
FAILURE CODE [DLF9LC] WHEEL SPEED SENSOR: TROUBLE (LEFT REAR)ย 1046
FAILURE CODE [DLF9MA] WHEEL SPEED SENSOR: DISCONNECTION (LEFT REAR)ย 1046
FAILURE CODE [DLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTIONย 1047
FAILURE CODE [DLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISAGREEMENT OF REVOLUTION SPEED SIGNALย 1049
FAILURE CODE [DLT4KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTIONย 1051
FAILURE CODE [DLT4MA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTIONย 1053
FAILURE CODE [DV00KB] BUZZER OUTPUT: SHORT CIRCUITย ย 1055
FAILURE CODE [DW2AKA] MAIN PRESSURE VARIABLE VALVE OUTPUT: DISCONNECTION 1057
FAILURE CODE [DW2AKB] MAIN PRESSURE VARIABLE VALVE OUTPUT CIRCUIT: GROUND FAULTย 1059
FAILURE CODE [DW2AKY] MAIN PRESSURE VARIABLE VALVE OUTPUT CIRCUIT: HOT SHORT 1061
FAILURE CODE [DW2AL1] MAIN PRESSURE VARIABLE VALVE: DEFECTIVE RESETย 1062
FAILURE CODE [DW2ALH] MAIN PRESSURE VARIABLE VALVE: MALFUNCTIONย 1064
FAILURE CODE [DW2BKA] MAIN OIL LEVEL SELECTOR VALVE OUTPUT: DISCONNECTIONย 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 SHORTย 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: DISCONNECTIONย 1072
FAILURE CODE [DW2CKB] TRANSMISSION LUBRICATION VARIABLE VALVE OUTPUT CIRCUIT: GROUND FAULT 1073
FAILURE CODE [DW2CKY] TRANSMISSION LUBRICATION VARIABLE VALVE OUTPUT CIRCUIT: HOT SHORTย 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)ย 1083
FAILURE CODE [DW72KZ] KICK-OUT SOLENOID OUTPUT SYSTEM TROUBLE: DISCONNECTION OR SHORT CIRCUITย 1085
FAILURE CODE [DW73KZ] FAILURE IN HOIST SELECT VALVE OUTPUT SYSTEM: DISCONNECTION OR SHORT CIRCUITย 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)ย 1091
FAILURE CODE [DWNBKA] ASR SHUT-OFF VALVE OUTPUT CIRCUIT: DISCONNECTION 1093
FAILURE CODE [DWNBKB] ASR SHUT-OFF VALVE OUTPUT CIRCUIT: GROUND FAULTย 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 9ย 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:DISCONNECTIONย 1103
FAILURE CODE [DX11KB] REAR BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE: SHORT CIRCUITย 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 CONTROLย 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 LINEย 1112
FAILURE CODE [DX12MA] FRONT BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE: ALFUNCTIONย 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 LINEย 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: DISCONNECTIONย 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)ย 1126
FAILURE CODE [DX18K4] ASR PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE (LEFT): TROUBLE (VALVE KEEPS OPERATING)ย 1127
FAILURE CODE [DX18KA] ASR PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE (LEFT) OUTPUT CIRCUIT:DISCONNECTIONย 1129
FAILURE CODE [DX18KB] ASR PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE (LEFT) OUTPUT CIRCUIT: GROUND FAULTย 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 10ย ย 1134
FAILURE CODE [DXH1KA] LOCKUP CLUTCH SOLENOID OUTPUT CIRCUIT: DISCONNECTION 1136
FAILURE CODE [DXH1KB] LOCK-UP CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUITย 1137
FAILURE CODE [DXH1KY] LOCKUP CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT TO POWER SOURCE LINEย 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 LINEย 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 LINEย 1150
FAILURE CODE [DXH4KA] 1ST CLUTCH SOLENOID OUTPUT CIRCUIT: DISCONNECTIONย 1153
FAILURE CODE [DXH4KB] 1ST CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUITย 1155
FAILURE CODE [DXH4KY] 1ST CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT TO POWER SOURCE LINE 1157
FAILURE CODE [DXH5KA] 2ND CLUTCH SOLENOID OUTPUT CIRCUIT: DISCONNECTIONย 1160
FAILURE CODE [DXH5KB] 2ND CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUITย 1162
FAILURE CODE [DXH5KY] 2ND CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT IN POWER SOURCEย 1164
FAILURE CODE [DXH6KA] 3RD CLUTCH SOLENOID OUTPUT CIRCUIT: DISCONNECTIONย 1167
FAILURE CODE [DXH6KB] 3RD CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUITย 1169
FAILURE CODE [DXH6KY] 3RD CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT TO POWER SOURCE LINE 1171
FAILURE CODE [DXH7KA] R CLUTCH SOLENOID OUTPUT CIRCUIT: DISCONNECTIONย 1174
FAILURE CODE [DXH7KB] R CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUITย 1176
FAILURE CODE [DXH7KY] R CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT TO POWER SOURCE LINE 1178
FAILURE CODE [DXHHKA] 4TH CLUTCH SOLENOID OUTPUT CIRCUIT: DISCONNECTIONย 1179
FAILURE CODE [DXHHKB] 4TH CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUITย 1181
FAILURE CODE [DXHHKY] 4TH CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT TO POWER SOURCE LINE 1183
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)ย 1187
BEFORE TROUBLESHOOTING OF ELECTRIC SYSTEMย 1189
CONTENTS OF TROUBLESHOOTING TABLEย 1190
E-1 ENGINE DOES NOT STARTย 1191
E-2 AUTOMATIC PREHEATING DOES NOT OPERATEย 1194
E-3 MACHINE MONITOR DOES NOT DISPLAY ALL, WHEN STARTING SWITCH IS TURNED ONย 1197
E-4 MACHINE MONITOR DOES NOT OPERATE WHEN STARTING SWITCH IS OFF 1199
E-5 ALARM BUZZER DOES NOT SOUNDย 1201
E-6 GAUGES OF MACHINE MONITOR, CAUTION LAMPS OR CHARACTER DISPLAY SECTION DO NOT DISPLAY PROPERLYย 1203
E-7 A SELECTION OF THE DISPLAY IN CHARACTER DISPLAY SECTION CANNOT BE CHANGEDย 1204
E-8 POWER MODE SELECTING FUNCTION DOES NOT OPERATE PROPERLYย 1207
E-9 AISS FUNCTION DOES NOT OPERATE PROPERLYย 1208
E-10 SEAT BELT CAUTION LAMP DOES NOT DISPLAY PROPERLYย 1209
E-11 TURN SIGNAL LAMP OR TURNING LAMP (HAZARD LAMP) DO NOT WORK PROPERLY 1210
E-12 NIGHT ILLUMINATION (LIGHTING) DOES NOT WORK PROPERLYย 1213
E-13 EMERGENCY STEERING DOES NOT OPERATEย ย 1225
E-14 HOIST LEVER DOES NOT OPERATE NORMALLYย ย 1230
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)ย 1233
CONTENTS OF TROUBLESHOOTING TABLEย 1235
H-1 MACHINE DOES NOT STARTย ย 1236
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (HUNTING)ย ย 1238
H-3 LOCKUP CANNOT BE CANCELLEDย ย 1238
H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING EXCESSIVEย 1239
H-5 TRANSMISSION DOES NOT SHIFT UPย ย 1240
H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELINGย 1242
H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR 1245
H-8 TORQUE CONVERTER OIL TEMPERATURE IS HIGHย ย 1247
H-9 TORQUE CONVERTER OIL PRESSURE IS LOWย ย 1248
H-10 FRONT BRAKE IS INEFFECTIVEย 1249
H-11 REAR BRAKE IS INEFFECTIVEย ย 1250
H-12 STEERING WHEEL IS HEAVYย ย 1251
H-13 STEERING WHEEL DOES NOT WORKย 1252
H-14 STEERING WHEEL VIBRATESย ย 1253
H-15 DUMP BODY LIFTING SPEED IS SLOWย ย 1254
H-16 DUMP BODY DOES NOT WORKย ย 1255
H-17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODYย 1256
TROUBLESHOOTING OF ENGINE (S-MODE)ย ย 1258
METHOD OF USING TROUBLESHOOTING CHARTSย ย 1260
S-1 STARTING PERFORMANCE IS POORย ย 1263
S-2 ENGINE DOES NOT STARTย 1264
S-3 ENGINE DOES NOT PICK UP SMOOTHLYย ย 1267
S-4 ENGINE STOPS DURING OPERATIONSย ย 1268
S-5 ENGINE DOES NOT ROTATE SMOOTHLYย 1269
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)ย ย 1270
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)ย ย 1272
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)ย 1273
S-9 OIL BECOMES CONTAMINATED QUICKLYย ย 1274
S-10 FUEL CONSUMPTION IS EXCESSIVEย ย 1275
S-11 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 1276
S-12 OIL PRESSURE DROPSย 1277
S-13 OIL LEVEL RISES (ENTRY OF COOLANT OR FUEL)ย 1278
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)ย 1279
S-15 ABNORMAL NOISE IS MADEย 1280
S-16 VIBRATION IS EXCESSIVEย 1281
50 DISASSEMBLY AND ASSEMBLYย ย 0
GENERAL INFORMATION ON DISASSEMBLY AND ASSEMBLYย 1283
HOW TO READ THIS MANUALย 1284
LIST OF ADHESIVESย 1286
SPECIAL TOOL LISTย 1289
SKETCHES OF SPECIAL TOOLSย 1290
ENGINE AND COOLING SYSTEMย 1292
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMPย ย 1293
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLYย ย 1295
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLYย 1303
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLYย 1310
POWER TRAIN, PART 1ย 1315
REMOVAL AND INSTALLATION OF FRONT DRIVE SHAFTย 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 ASSEMBLIESย 1328
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION ASSEMBLYย 1340
POWER TRAIN, PART 2ย 1373
DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLYย 1374
DISASSEMBLY AND ASSEMBLY OF FRONT BRAKE ASSEMBLYย ย 1387
DISASSEMBLY AND ASSEMBLY OF REAR BRAKE ASSEMBLYย 1394
90 DIAGRAMS AND DRAWINGSย 0
HYDRAULIC DIAGRAMS AND DRAWINGSย 1407
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAMย 1409
STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAMย ย 1411
BRAKE HYDRAULIC CIRCUIT DIAGRAMย 1413
BRAKE HYDRAULIC CIRCUIT DIAGRAM (ASR SPECIFICATION)ย 1415
BRAKE HYDRAULIC CIRCUIT DIAGRAM (ABS SPECIFICATION)ย 1417
BRAKE HYDRAULIC CIRCUIT DIAGRAM (ASR AND ABS SPECIFICATION)ย 1419
ELECTRICAL DIAGRAMS AND DRAWINGSย ย 1423
ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (1/3)ย ย 1425
ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (2/3)ย ย 1426
ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (3/3)ย ย 1427
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (1/3)ย 1428
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (2/3)ย 1429
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (3/3)ย 1430
ELECTRICAL CIRCUIT DIAGRAM FOR VHMSย 1431
ELECTRICAL CIRCUIT DIAGRAM FOR ABS (OUTSIDE CAB)ย ย 1432
ELECTRICAL CIRCUIT DIAGRAM FOR ABS (INSIDE CAB)ย 1433
ELECTRICAL CIRCUIT DIAGRAM FOR ASRย ย 1434
CONNECTORS TABLE AND ARRANGEMENT DRAWINGย ย 1435
DESCRIPTION:
Komatsu HD785-7 Dump Truck Shop Manual SEN01274-04-N1-00 – PDF DOWNLOADย
SERIAL NUMBERS N10001 โ N10560
How to read the shop manualย
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 ยS modeย 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 26/12/24ย
