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Komatsu HD785-7 Dump Truck Shop Manual SEN05900-01 – PDF DOWNLOAD
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Komatsu HD785-7 Dump Truck Shop Manual
SERIAL NUMBERS 30001 and up
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Description
Komatsu HD785-7 Dump Truck Shop Manual SEN05900-01
FILE DETAILS:
Komatsu HD785-7 Dump Truck Shop Manual
Brands: Komatsu
Equipment Type: Dump Truck
Manuals Type: Shop Manual
Machine Model: HD785-7
Serial Number: 30001 and up
Book Code: SEN05900-01
Language: English
Pages: 1925
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu HD785-7 Dump Truck Shop Manual
How to read the shop manual:
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section contains the index, foreword, safety and basic information. If any revision is made, the LIST OF REVISED PAGES will be added.
01. Specification:
This section explains the specifications of the machine.
10. Structure and function:
This section explains the structure and function of each component. It serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting.
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 tools and measuring methods for testing and adjusting, as well as the adjusting method of each part. The standard values and judgment criteria for “Testing and adjusting” are
explained in “Standard value table”.
40. Troubleshooting:
This section explains how to find out failed parts and how to repair them. The troubleshooting is dividedby 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.
60. Maintenance standard:
This section gives maintenance standard values of each component. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
80. Appendix:
This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment not classifiable in other sections.
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 remanufacturing and repairing engine and replacing parts.
TABLE OF CONTENTS:
Komatsu HD785-7 Dump Truck Shop Manual
Cover.................................................................................................................................................................... 1 00 Index and foreword.................................................................................................................................................... 0 Index................................................................................................................................................................ 3 Composition of shop manual....................................................................................................................................... 4 Table of contents................................................................................................................................................ 6 Foreword and general information..................................................................................................................................... 23 Foreword and general informationSafety notice.................................................................................................................... 24 How to read the shop manual...................................................................................................................................... 29 Explanation of terms for maintenance standard.................................................................................................................... 31 Handling of hydraulic components................................................................................................................................. 33 Method of disconnecting and connecting push-pull type coupler.................................................................................................... 35 Handling of electric equipment................................................................................................................................... 38 How to read electric wire code................................................................................................................................... 48 Precautions when performing work................................................................................................................................. 51 Standard tightening torque table................................................................................................................................. 54 List of Abbreviation............................................................................................................................................. 58 Conversion table................................................................................................................................................. 62 01 Specification......................................................................................................................................................... 0 Specification and technical data..................................................................................................................................... 69 Specification drawing............................................................................................................................................ 70 Specifications................................................................................................................................................... 72 Weight table..................................................................................................................................................... 75 Fuel, coolant and lubricants..................................................................................................................................... 76 10 Structure, function andmaintenance standard........................................................................................................................... 0 Engine and cooling system............................................................................................................................................ 81 Radiator, brake, torque converter oil cooler, aftercooler, steering, hoist oil cooler........................................................................... 82 Fuel system...................................................................................................................................................... 84 Power train, Part 1.................................................................................................................................................. 87 Power train skeleton............................................................................................................................................. 88 Output shaft..................................................................................................................................................... 90 Drive shaft...................................................................................................................................................... 92 Torque converter and transmission hydraulic piping............................................................................................................... 94 Brake cooling oil control valve (BCV)............................................................................................................................ 96 Torque converter................................................................................................................................................. 98 Torque converter valve........................................................................................................................................... 105 Transmission..................................................................................................................................................... 108 Transmission control valve....................................................................................................................................... 136 ECMV............................................................................................................................................................. 138 Power train, Part 2.................................................................................................................................................. 149 Axle............................................................................................................................................................. 150 Differential..................................................................................................................................................... 152 Final drive...................................................................................................................................................... 153 Wheels........................................................................................................................................................... 154 Steering system...................................................................................................................................................... 157 Steering column.................................................................................................................................................. 158 Steering linkage................................................................................................................................................. 159 Brake system......................................................................................................................................................... 163 Brake piping..................................................................................................................................................... 164 Brake valve...................................................................................................................................................... 166 Secondary brake valve............................................................................................................................................ 169 Accumulator charge valve......................................................................................................................................... 170 Accumulator...................................................................................................................................................... 175 Slack adjuster................................................................................................................................................... 177 Brake, parking brake............................................................................................................................................. 181 Parking brake solenoid........................................................................................................................................... 187 Retarder control valve........................................................................................................................................... 188 Exhaust brake.................................................................................................................................................... 189 Undercarriage and frame.............................................................................................................................................. 193 Suspension....................................................................................................................................................... 194 Suspension cylinder.............................................................................................................................................. 196 Rear axle support................................................................................................................................................ 204 Hydraulic system..................................................................................................................................................... 207 Steering and hoist hydraulic piping.............................................................................................................................. 208 Steering, hoist filter (high pressure circuit)................................................................................................................... 210 Dump body control................................................................................................................................................ 212 Power ladder system (If equipped)................................................................................................................................ 214 Hydraulic tank................................................................................................................................................... 220 Steering valve................................................................................................................................................... 221 Crossover relief valve........................................................................................................................................... 225 Steering cylinder................................................................................................................................................ 226 Steering control valve........................................................................................................................................... 227 Hoist valve...................................................................................................................................................... 236 Dump control valve (EPC valve)................................................................................................................................... 242 Hydraulic pump................................................................................................................................................... 244 Work equipment (Body)................................................................................................................................................ 249 Auto greasing system (If equipped)............................................................................................................................... 250 Hoist cylinder................................................................................................................................................... 261 Cab and its attachments.............................................................................................................................................. 263 ROPS cab......................................................................................................................................................... 264 Air conditioner.................................................................................................................................................. 265 Rear view monitor system......................................................................................................................................... 274 Controller related............................................................................................................................................... 279 Electrical system, Part 1............................................................................................................................................ 281 Machine monitor system........................................................................................................................................... 282 Electrical system, Part 2............................................................................................................................................ 307 Automatic shift control system................................................................................................................................... 308 External power supply heater..................................................................................................................................... 328 Automatic emergency steering system.............................................................................................................................. 330 Automatic suspension system...................................................................................................................................... 334 Retarder control system.......................................................................................................................................... 337 Dump control lever............................................................................................................................................... 350 Ladder control function (If equipped)............................................................................................................................ 354 Electrical system, Part 3............................................................................................................................................ 357 VHMS controller related.......................................................................................................................................... 358 ABS/ASR system................................................................................................................................................... 384 Altitude setting function........................................................................................................................................ 402 Speed limit function............................................................................................................................................. 405 Electrical system, Part 4............................................................................................................................................ 411 Sensors, switches................................................................................................................................................ 412 20 Standard value table.................................................................................................................................................. 0 Standard service value table......................................................................................................................................... 431 Standard value table for engine.................................................................................................................................. 432 Standard value table for machine................................................................................................................................. 434 30 Testing and adjusting................................................................................................................................................. 0 Testing and adjusting, Part 1........................................................................................................................................ 447 Testing and adjusting tools list................................................................................................................................. 449 Sketch of special tool........................................................................................................................................... 454 Testing engine speed............................................................................................................................................. 455 Testing air supply pressure (boost pressure)..................................................................................................................... 456 Testing exhaust temperature...................................................................................................................................... 458 Testing exhaust gas color........................................................................................................................................ 460 Adjustment of valve clearance.................................................................................................................................... 462 Testing compression pressure..................................................................................................................................... 464 Testing blow-by pressure......................................................................................................................................... 466 Testing engine oil pressure...................................................................................................................................... 467 Handling of fuel system devices.................................................................................................................................. 468 Releasing residual pressure from fuel system..................................................................................................................... 468 Testing fuel pressure............................................................................................................................................ 469 Reduced cylinder mode operation1................................................................................................................................. 470 No-injection cranking............................................................................................................................................ 470 Testing leakage-from pressure limiter and return rate from injector.............................................................................................. 471 Bleeding air from fuel circuit (Standard spec.).................................................................................................................. 474 Bleeding air from fuel circuit (Extra low-grade fuel spec.)...................................................................................................... 478 Testing the fuel circuit for leakage1............................................................................................................................ 480 Replacement and adjustment of fan belt........................................................................................................................... 481 Testing and adjusting alternator belt tension.................................................................................................................... 482 Testing and adjusting air conditioner compressor belt............................................................................................................ 483 Testing and adjusting, Part 2........................................................................................................................................ 485 Testing torque converter stall speed............................................................................................................................. 487 Testing power train oil pressure................................................................................................................................. 489 Adjusting transmission speed sensor.............................................................................................................................. 497 Testing and adjusting brake oil pressure......................................................................................................................... 498 Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas............................................................ 501 Testing brake performance........................................................................................................................................ 506 Bleeding air from brake circuit.................................................................................................................................. 508 Bleeding air from ASR circuit (if equipped)...................................................................................................................... 510 Testing wear of front brake disc................................................................................................................................. 511 Testing wear of rear brake disc.................................................................................................................................. 512 Method of releasing parking brake in an emergency................................................................................................................ 513 Testing and adjusting front suspension cylinder.................................................................................................................. 514 Testing and adjusting rear suspension cylinder................................................................................................................... 518 Testing and adjusting front suspension cylinder (Automatic suspension specification)............................................................................. 522 Testing and adjusting hydraulic pressure in steering, hoist circuit.............................................................................................. 523 Testing and adjusting oil pressure in dump EPC circuit........................................................................................................... 526 Air bleeding from steering cylinder.............................................................................................................................. 527 Procedure for raising dump body in emergency..................................................................................................................... 528 Adjusting body positioner sensor................................................................................................................................. 529 Handling of high voltage circuit of engine controller............................................................................................................ 531 Adjusting transmission controller................................................................................................................................ 531 Method for emergency escape at electrical system failure......................................................................................................... 532 Testing and adjusting ladder potentiometer....................................................................................................................... 536 Calibration method of ladder position............................................................................................................................ 537 Testing and adjusting, Part 3........................................................................................................................................ 541 Setting and adjusting of devices................................................................................................................................. 542 Testing and adjusting, Part 4........................................................................................................................................ 557 Special functions of machine monitor (EMMS)...................................................................................................................... 558 Testing and adjusting, Part 5........................................................................................................................................ 629 Opening ORBCOMM terminal......................................................................................................................................... 630 VHMS controller initial setting procedure........................................................................................................................ 632 Precautions for replacing VHMS controller........................................................................................................................ 657 Pm Clinic check sheet............................................................................................................................................ 663 Initial setting of payload meter................................................................................................................................. 667 Setting of payload meter built in VHMS........................................................................................................................... 668 40 Troubleshooting....................................................................................................................................................... 0 Failure code table and fuse locations................................................................................................................................ 677 Failure codes table.............................................................................................................................................. 678 Fuse locations................................................................................................................................................... 694 General information on troubleshooting............................................................................................................................... 701 Points to remember when troubleshooting.......................................................................................................................... 702 Sequence of events in troubleshooting............................................................................................................................ 703 Check before troubleshooting..................................................................................................................................... 704 Classification and procedures for troubleshooting................................................................................................................ 705 Contents of troubleshooting table................................................................................................................................ 706 Connector list and layout........................................................................................................................................ 708 Connection table for connector pin numbers....................................................................................................................... 727 T- branch box and T- branch adapter table........................................................................................................................ 763 Troubleshooting by failure code, Part 1.............................................................................................................................. 767 Failure code [1500L0] Dual engagement............................................................................................................................ 769 Failure code [15B0NX] Transmission oil filter: Clogging.......................................................................................................... 770 Failure code [15F0KM] R -> F shifting abuse 1: Mistake in operation.............................................................................................. 772 Failure code [15F0MB] R -> F shifting abuse 2: Mistake in operation............................................................................................. 772 Failure code [15F7KM] Forward clutch disk abuse: Mistake in operation or setting................................................................................. 773 Failure code [15G0MW] R clutch: Slipping......................................................................................................................... 774 Failure code [15G7KM] Reverse clutch disk abuse: Mistake in operation or setting................................................................................. 776 Failure code [15H0MW] Hi clutch: Slipping........................................................................................................................ 778 Failure code [15J0MW] Lo clutch: Slipping........................................................................................................................ 780 Failure code [15K0MW] 1st clutch: Slipping....................................................................................................................... 782 Failure code [15L0MW] 2nd clutch: Slipping....................................................................................................................... 784 Failure code [15M0MW] 3rd clutch: Slipping....................................................................................................................... 786 Failure code [15N0MW] 4th clutch: Slipping....................................................................................................................... 788 Failure code [15SBL1] R clutch solenoid: Fill signal is ON when command current is OFF........................................................................... 790 Failure code [15SBMA] R clutch solenoid: Malfunction............................................................................................................. 792 Failure code [15SCL1] Hi clutch solenoid: Fill signal is ON when command current is OFF.......................................................................... 794 Failure code [15SCMA] Hi clutch solenoid: Malfunction............................................................................................................ 797 Failure code [15SDL1] Lo clutch solenoid: Fill signal is ON when command current is OFF.......................................................................... 798 Failure code [15SDMA] Lo clutch solenoid: Malfunction............................................................................................................ 801 Failure code [15SEL1] 1st clutch solenoid: Fill signal is ON when command current is OFF......................................................................... 802 Failure code [15SEMA] 1st clutch solenoid: Malfunction........................................................................................................... 805 Troubleshooting by failure code, Part 2.............................................................................................................................. 807 Failure code [15SFL1] 2nd clutch solenoid: Fill signal is ON when command current is OFF......................................................................... 810 Failure code [15SFMA] 2nd clutch solenoid: Malfunction........................................................................................................... 813 Failure code [15SGL1] 3rd clutch solenoid: Fill signal is ON when command current is OFF......................................................................... 814 Failure code [15SGMA] 3rd clutch solenoid: Malfunction........................................................................................................... 817 Failure code [15SHL1] 4th clutch solenoid: Fill signal is ON when command current is OFF......................................................................... 818 Failure code [15SHMA] 4th clutch solenoid: Malfunction........................................................................................................... 821 Failure code [15SJMA] Lockup clutch solenoid: Malfunction........................................................................................................ 822 Failure code [2F00KM] Parking brake: Mistake in operation or setting............................................................................................. 824 Failure code [2G42ZG] Accumulator: Oil pressure reduction (Front)................................................................................................ 827 Failure code [2G43ZG] Accumulator: Oil pressure reduction (Rear)................................................................................................. 827 Failure code [989A00] Engine over run prevention command signal: Operating....................................................................................... 828 Failure code [989D00] Rear section tipping over alarm: Alarm isactivated......................................................................................... 828 Failure code [989X00] Overspeed alarm: Alarm operation........................................................................................................... 829 Failure code [989Y00] Overload alarm: Speed limit function operation............................................................................................. 829 Failure code [989Z00] Parking Brake Interlock Caution............................................................................................................ 830 Failure code [A570NX] Engine oil filter: Clogging................................................................................................................ 832 Failure code [AA10NX] Air cleaner element: Clogging.............................................................................................................. 834 Failure code [AB00L4] Alternator: Failure on battery charge circuit (R terminal signal is present and engine is stopped)......................................... 836 Failure code [AB00MA] Alternator: Malfunction.................................................................................................................... 838 Failure code [AB00MB] Alternator: Failure on battery charge circuit (Absence of R terminal signal and detection error)........................................... 840 Failure code [B@BAZG] Abnormal lowering of engine oil pressure: Lowering of oil pressure......................................................................... 842 Failure code [B@BAZK] Engine oil: Level too low.................................................................................................................. 844 Failure code [B@BCNS] Engine: Overheat........................................................................................................................... 846 Failure code [B@BCZK] Lowering of radiator coolant: Lowering of level............................................................................................ 848 Failure code [B@BFZK] Lowering of fuel level..................................................................................................................... 850 Failure code [B@C6NS] Brake cooling oil: Overheating (Front)..................................................................................................... 851 Failure code [B@C7NS] Brake cooling oil: Overheating (Rear)...................................................................................................... 852 Failure code [B@CENS] Overheating of torque converter oil........................................................................................................ 854 Failure code [B@GAZK] Battery electrolyte level: Lowering of level............................................................................................... 855 Failure code [B@JANS] Steering oil temperature: Overheat......................................................................................................... 856 Troubleshooting by failure code, Part 3.............................................................................................................................. 859 Failure code [CA111] Engine controller (Left bank): Internal abnormality1........................................................................................ 862 Failure code [CB111] Engine controller (Right bank): Internal abnormality........................................................................................ 864 Failure code [CA115] Abnormal engine Ne and Bkup speed sensors (Left bank): Abnormal speed sensor signal......................................................... 866 Failure code [CB115] Abnormal engine Ne and Bkup speed sensors (Right bank): Abnormal speed sensor signal........................................................ 867 Failure code [CA122] Charge pressure sensor too high (At left bank only): Excessively high voltage detected...................................................... 868 Failure code [CA123] Charge pressure sensor too low (At left bank only): Excessively low voltage detected........................................................ 870 Failure code [CA131] Throttle sensor high error (At left bank only).............................................................................................. 872 Failure code [CA132] Throttle sensor low error (At left bank only)............................................................................................... 874 Failure code [CA135] Oil pressure sensor too high (At left bank only):Excessively high voltage detected.......................................................... 876 Failure code [CA141] Oil pressure sensor too low (At left bank only):Excessively low voltage detected............................................................ 878 Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected...................................................................... 880 Failure code [CA145] Coolant temperature sensor too low (At left bank only): Excessively low voltage detected.................................................... 882 Failure code [CA153] Charge temperature sensor too high (At left bank only): Excessively high voltage detected................................................... 884 Failure code [CA154] Charge temperature sensor too low (At left bank only): Excessively low voltage detected..................................................... 886 Failure code [CA187] Sensor power supply (2) abnormally low level (Left bank): Low voltage detection............................................................. 888 Failure code [CB187] Sensor power supply (2) abnormally low level (Right bank): Low voltage detection............................................................ 888 Failure code [CA212] Engine oil temperature sensor abnormally high level (At left bank only): High voltage detection............................................. 890 Failure code [CA213] Engine oil temperature sensor abnormally low level (At left bank only): Low voltage detection............................................... 892 Failure code [CA221] Atmospheric pressure sensor too high (At left bank only): Excessively high voltage detected................................................. 894 Failure code [CA222] Atmospheric pressure sensor too low (At left bank only): Excessively low voltage detected................................................... 896 Failure code [CA227] Sensor power source (2) too high (Left bank): Excessively high voltage detected............................................................. 898 Failure code [CB227] Sensor power supply (2) abnormally high level (Right bank): High voltage detection.......................................................... 900 Failure code [CA234] Engine over speed (At left bank only): Excessively high speed............................................................................... 902 Failure code [CA238] Abnormal power source for Ne speed sensor (At left bank only): Excessively low voltage detected............................................. 904 Failure code [CB238] Abnormal power source for Ne speed sensor (At right bank only): Excessively low voltage detected............................................ 906 Failure code [CA263] Fuel temperature sensor too high (Left bank): Excessively high voltage detected............................................................. 908 Failure code [CB263] Fuel temperature sensor too high (Right bank): Excessively high voltage detected............................................................ 910 Failure code [CA265] Fuel temperature sensor abnormally low level (Left bank): Low voltage detection............................................................. 912 Failure code [CB265] Fuel temperature sensor abnormally low level (Right bank): Low voltage detection............................................................ 912 Failure code [CA271] PCV1 short circuit (Left bank): Short circuit............................................................................................... 913 Failure code [CB271] PCV1 short circuit (Right bank): Short circuit.............................................................................................. 914 Failure code [CA272] PCV1 disconnection (Left bank): Disconnection............................................................................................... 915 Failure code [CB272] PCV1 disconnection (Right bank): Disconnection1............................................................................................. 916 Failure code [CA273] PCV2 short circuit (Left bank): Short circuit............................................................................................... 917 Failure code [CB273] PCV2 short circuit (Right bank): Short circuit.............................................................................................. 918 Failure code [CA274] PCV2 disconnection (Left bank): Disconnection............................................................................................... 919 Failure code [CB274] PCV2 disconnection (Right bank): Disconnection1............................................................................................. 920 Troubleshooting by failure code, Part 4.............................................................................................................................. 923 Failure code [CA322] Injector No. 1 (L/B No.1) system disconnection or short circuit (Left bank): Disconnection, short circuit................................... 926 Failure code [CA323] Injector No. 5 (L/B No.5) system disconnection or short circuit (Left bank): Disconnection, short circuit................................... 928 Failure code [CA324] Injector No. 3 (L/B No.3) system disconnection or short circuit (Left bank): Disconnection, short circuit................................... 930 Failure code [CA325] Injector No. 6 (L/B No.6) system disconnection or short circuit (Left bank): Disconnection, short circuit................................... 932 Failure code [CA331] Injector No. 2 (L/B No.2) system disconnection or short circuit (Left bank): Disconnection, short circuit................................... 934 Failure code [CA332] Injector No. 4 (L/B No.4) system disconnection or short circuit (Left bank): Disconnection, short circuit................................... 936 Failure code [CA342] Engine controller data mismatch (Left bank): Mismatch....................................................................................... 938 Failure code [CB342] Engine controller data mismatch (Right bank): Mismatch...................................................................................... 938 Failure code [CA351] Abnormal injector drive circuit (Left bank): Abnormal circuit............................................................................... 940 Failure code [CB351] Injector drive circuit abnormality (Right bank): Circuit abnormality........................................................................ 942 Failure code [CA352] Sensor power supply (1) abnormally low level (Left bank): Low voltage detection............................................................. 944 Failure code [CB352] Sensor power supply (1) abnormally low level (Right bank): Low voltage detection............................................................ 944 Failure code [CA386] Sensor power supply (1) abnormally high level (Left bank): High voltage detection........................................................... 946 Failure code [CB386] Sensor power supply (1) abnormally high level (Right bank): High voltage detection.......................................................... 948 Failure code [CA431] Trouble in idle validation switch........................................................................................................... 950 Failure code [CA432] Idle validation action error................................................................................................................ 954 Failure code [CA441] Power supply voltage abnormally low level (Left bank): Low voltage detection................................................................ 955 Failure code [CB441] Power supply voltage abnormally low level (Right bank): Low voltage detection............................................................... 955 Failure code [CA442] Power supply voltage abnormally high level (Left bank): High voltage detection.............................................................. 956 Failure code [CB442] Power supply voltage abnormally high level (Right bank): High voltage detection............................................................. 956 Failure code [CA449] Common rail abnormally high pressure (2) (Left bank): Abnormally high pressure occurrence................................................... 957 Failure code [CB449] Common rail abnormally high pressure (2) (Right bank): Abnormally high pressure occurrence.................................................. 957 Failure code [CA451] Common rail pressure sensor too high (Left bank): Excessively high voltage detected......................................................... 958 Failure code [CB451] Common rail pressure sensor abnormally high level (Right bank): High voltage detection...................................................... 960 Failure code [CA452] Common rail pressure sensor abnormally low level (Left bank): Abnormally low voltage detection.............................................. 962 Failure code [CB452] Common rail pressure sensor abnormally low level (Right bank): Abnormally low voltage detection............................................. 962 Failure code [CA553] Common rail pressure too high (1) (Left bank): Excessively high pressure detected........................................................... 963 Failure code [CB553] Common rail pressure too high (1) (Right bank): Excessively high pressure detected.......................................................... 964 Failure code [CA554] In-range error in common rail pressure sensor (Left bank): In-range error................................................................... 965 Failure code [CA559] Loss of pressure feed from supply pump (1) (Left bank): Loss of pressure feed detected...................................................... 966 Failure code [CB554] In-range error in common rail pressure sensor (Right bank): In-range error.................................................................. 965 Failure code [CA559] Loss of pressure feed from supply pump (1) (Left bank): Loss of pressure feed detected...................................................... 966 Failure code [CB559] Loss of pressure feed from supply pump (1) (Right bank): Loss of pressure feed detected..................................................... 970 Failure code [CA689] Abnormal engine Ne speed sensor (Left bank): Abnormal signal................................................................................ 974 Failure code [CB689] Abnormal engine Ne speed sensor (Right bank): Abnormal signal............................................................................... 976 Failure code [CA691] Intake air temperature sensor abnormally high level (At left bank only): High voltage detection............................................. 978 Failure code [CA692] Intake air temperature sensor abnormally low level (At left bank only): Low voltage detection............................................... 980 Failure code [CA731] Abnormal engine Bkup speed sensor phase (Left bank): Abnormal phase......................................................................... 981 Failure code [CB731] Abnormal engine Bkup speed sensor phase (Right bank): Abnormal phase........................................................................ 981 Troubleshooting by failure code, Part 5.............................................................................................................................. 983 Failure code [CA757] Loss of all engine controller data (Left bank): Loss of all data............................................................................ 985 Failure code [CB757] Loss of all engine controller data (Right bank): Loss of all data........................................................................... 985 Failure code [CA778] Abnormal engine Bkup speed sensor (Left bank): Abnormal Bkup signal......................................................................... 986 Failure code [CB778] Engine Bkup speed sensor abnormality (Right bank): Bkup signal error........................................................................ 988 Failure code [CA781] Inter-multicontroller communication error (Left bank): Communication error.................................................................. 990 Failure code [CB781] Inter-multicontroller communication error (Right bank): Communication error................................................................. 992 Failure code [CA1257] Multicontroller distinction wiring harness key error (Left bank): Distinction error........................................................ 993 Failure code [CB1257] Multicontroller distinction wiring harness keyerror (Right bank): Distinction error....................................................... 994 Failure code [CB1548] Injector #7 (R/B #1) system disconnection/shortcircuit (Right bank): Disconnection/Short circuit.......................................... 996 Failure code [CB1549] Injector #8 (R/B #2) system disconnection/short circuit (Right bank): Disconnection/Short circuit.......................................... 998 Failure code [CB1551] Injector #10 (R/B #4) system disconnection/short circuit (Right bank): Disconnection/Short circuit.........................................1000 Failure code [CB1552] Injector #11 (R/B #5) system disconnection/short circuit (Right bank): Disconnection/Short circuit.........................................1002 Failure code [CB1553] Injector #12 (R/B #6) system disconnection/short circuit (Right bank): Disconnection/Short circuit.........................................1004 Failure code [CB1622] Injector #9 (R/B #3) system disconnection/short circuit (Right bank): Disconnection/Short circuit..........................................1006 Failure code [CA1633] KOMNET abnormality (Left bank): Communication error........................................................................................1008 Failure code [CA2185] Throttle sensor supply voltage high error..................................................................................................1010 Failure code [CA2186] Throttle sensor power supply low error.....................................................................................................1012 Failure code [CA2249] Loss of pressure feed from supply pump (2) (Left bank): Loss of pressure feed detected.....................................................1013 Failure code [CB2249] Loss of pressure feed from supply pump (2) (Right bank): Loss of pressure feed detected....................................................1013 Failure code [CA2555] Intake heater relay voltage low error (Left bank)..........................................................................................1014 Failure code [CA2556] Intake heater relay voltage high error (Left bank)1........................................................................................1016 Troubleshooting by failure code, Part 6..............................................................................................................................1019 Failure code [D180KA] Preheating relay output system: Disconnection..............................................................................................1022 Failure code [D180KB] Preheating relay output system: Grounding fault............................................................................................1023 Failure code [D180KY] Preheating relay output system: Hot short circuit..........................................................................................1024 Failure code [D19HKB] Stop lamp relay output system: Short circuit...............................................................................................1026 Failure code [D1EFKA] Pre-lubrication start relay output system: Disconnection...................................................................................1028 Failure code [D1EFKB] Pre-lubrication start relay output system: Grounding fault.................................................................................1030 Failure code [D1EFKY] Pre-lubrication start relay output system: Hot short circuit...............................................................................1032 Failure code [D1EMKA] Disconnection of Parking Interlock Relay Output Circuit....................................................................................1034 Failure code [D1EMKB] Ground Fault of Parking Interlock Relay Output Circuit.....................................................................................1035 Failure code [D1EMKY] Hot Short of Parking Interlock Relay Output Circuit........................................................................................1036 Failure code [D1ENKZ] Failure of Power Ladder Power Supply Relay Output System...................................................................................1037 Failure code [D1EPKA] Disconnection of Power Ladder Pump Drive Relay Output Circuit..............................................................................1038 Failure code [D1EPKB] Ground Fault of Power Ladder Pump Drive Relay Output Circuit...............................................................................1039 Failure code [D1EPKY] Hot Short of Power Ladder Pump Drive Relay Output Circuit..................................................................................1040 Failure code [D1EQKA] Disconnection of Power Ladder Buzzer Relay Output Circuit..................................................................................1041 Failure code [D1EQKB] Ground Fault of Power Ladder Buzzer Relay Output Circuit...................................................................................1042 Failure code [D1EQKY] Hot Short of Power Ladder Buzzer Relay Output Circuit......................................................................................1043 Failure code [D1ERKA] Open Circuit in Power Ladder Raise Solenoid Relay Output Circuit...........................................................................1044 Failure code [D1ERKB] Ground Fault of Power Ladder Raise Solenoid Relay Output Circuit...........................................................................1045 Failure code [D1ERKY] Hot Short in Power Ladder Raise Solenoid Relay Output Circuit..............................................................................1046 Failure code [D1ESKA] Open Circuit in Power Ladder Lower Solenoid Relay Output Circuit...........................................................................1047 Failure code [D1ESKB] Ground Fault of Power Ladder Lower Solenoid Relay Output Circuit...........................................................................1048 Failure code [D1ESKY] Hot Short in Power Ladder Lower Solenoid Relay Output Circuit..............................................................................1049 Failure code [DAF9KM] Wrong connection of connector..............................................................................................................1050 Failure code [DAFRKR] Abnormal CAN communication (machine monitor): Abnormal communication.......................................................................1051 Failure code [DAQ0KK] Transmission controller direct power supply: Lowering of power supply voltage..............................................................1052 Failure code [DAQ0KT] Transmission controller nonvolatile memory: Abnormality in controller......................................................................1054 Failure code [DAQ2KK] Transmission controller solenoid power supply: Power supply voltage too low................................................................1056 Failure code [DAQ9KQ] Transmission controller: Disagreement of model selection...................................................................................1058 Failure code [DAQRKR] Abnormality in CAN communication (Transmission)............................................................................................1059 Failure code [DAQRMA] Transmission controller option setting: Malfunction........................................................................................1064 Failure code [DB10KT] Retarder controller nonvolatile memory: Abnormality in controller..........................................................................1064 Failure code [DB12KK] Retarder controller solenoid power supply: Power supply system trouble.....................................................................1065 Failure code [DB13KK] Retarder controller battery direct power supply: Power supply voltage too low..............................................................1067 Failure code [DB19KQ] Disagreement of model selection (Retarder controller)......................................................................................1069 Failure code [DB1RKR] CAN communication (retarder controller): Communication disabled............................................................................1070 Failure code [DB1RMA] Disagreement of option setting (Retarder controller).......................................................................................1074 Failure code [DB2RKR] CAN communication (engine controller): Communication disabled..............................................................................1075 Failure code [dB2RKR] CAN communication (engine controller): Communication disabled..............................................................................1083 Failure code [DBB0KK] or VHMS_LED display: "n9" -> "01" VHMS controller: Low power supply voltage (input)........................................................1090 Failure code [DBB0KQ] (or VHMS_LED display: "nF" -> "11") VHMS controller: Disagreement of model selection signals...............................................1092 Failure code [DBB3KK] (or VHMS_LED display: "n9" -> "05") VHMS controller battery power supply: Low power supply voltage (input).................................1094 Failure code [DBB5KP] (or VHMS_LED display: "n9" -> "04") VHMS controller 5 V power supply output: Low output voltage............................................1096 Failure code [DBB6KP] (or VHMS_LED display: "n9" -> "02") VHMS controller 24 V power supply output: Low output voltage...........................................1098 Failure code [DBB7KP] (or VHMS_LED display: "n9" -> "03") VHMS controller 12 V power supply output: Low output voltage...........................................1100 Failure code [DBBQKR] (or VHMS_LED display: "n8" -> "02") VHMS controller CAN communication: Defective communication (Abnormality in target component system)....1101 Failure code [DBC0KT] Abnormality of Non-volatile Memory.........................................................................................................1102 Failure code [DBC2KK] ABS controller solenoid power supply: Power supply system trouble..........................................................................1104 Failure code [DBC2KK] Solenoid Power Supply: Low Voltage.........................................................................................................1106 Failure code [DBC3KK] ABS controller battery direct power supply: Power supply voltage too low...................................................................1108 Failure code [DBC3KK] Direct Battery Power Supply: Low Voltage...................................................................................................1110 Failure code [DBC9KQ] Disagreement of model selection (ABS controller)...........................................................................................1112 Failure code [DBCRKR] Abnormality in CAN communication (ABS).....................................................................................................1113 Failure code [DBCRMA] Disagreement of option setting (ABS controller)............................................................................................1117 Failure code [DBG2KK] Solenoid power supply: Low voltage.........................................................................................................1118 Failure code [DBG3KK] Battery direct power supply: Low voltage...................................................................................................1120 Failure code [DBG9KQ] Model selection signal: Abnormal...........................................................................................................1122 Failure code [DDD7KX] Trouble in travel speed setting switch system: Out of input signal range...................................................................1124 Failure code [DDD8KA] ARSC system switch system: Disconnection (If equipped).....................................................................................1126 Failure code [DDD8KB] ARSC system switch system: Short circuit (If equipped).....................................................................................1128 Failure code [DDD9KA] ABS system switch system: Disconnection....................................................................................................1130 Failure code [DDD9KB] ABS system switch system: Short circuit....................................................................................................1132 Failure code [DDDAKA] ASR system switch: Disconnection...........................................................................................................1134 Failure code [DDDAKB] ASR system switch: Short circuit...........................................................................................................1136 Failure code [DDDGL4] Failure of ladder manual operation switch CH1 (inside cab) system..........................................................................1138 Failure code [DDDHL4] Failure of ladder manual operation switch CH2 (outside cab) system.........................................................................1140 Failure code [DDE2KB] Engine oil pressure switch error: Grounding fault..........................................................................................1142 Failure code [DDE2L6] Engine oil pressure switch error: Disconnection or hot short circuit.......................................................................1144 Failure code [DDP6L4] Service brake pressure switch trouble (Rear)...............................................................................................1146 Failure code [DDTHKA] Hi clutch fill switch: Disconnection.......................................................................................................1148 Failure code [DDTJKA] Lo clutch fill switch: Disconnection.......................................................................................................1150 Failure code [DDTKKA] 1st clutch fill switch: Disconnection......................................................................................................1152 Failure code [DDTLKA] 2nd clutch fill switch: Disconnection......................................................................................................1154 Failure code [DDTMKA] 3rd clutch fill switch: Disconnection......................................................................................................1156 Failure code [DDTNKA] R clutch fill switch: Disconnection........................................................................................................1158 Failure code [DDTPKA] 4th clutch fill switch: Disconnection......................................................................................................1160 Failure code [DDU1KA] Open Circuit in Parking Brake Operation Input Circuit......................................................................................1162 Failure code [DF10KA] Gear shift lever: Disconnection............................................................................................................1163 Failure code [DF10KB] Gear shift lever: Short circuit............................................................................................................1166 Failure code [DGE5KX] or VHMS_LED display: "n4" -> "01" Atmospheric temperature sensor: Out of input signal range...............................................1170 Failure code [DGF1KX] Transmission oil temperature sensor: Out of input signal range.............................................................................1172 Failure code [DGR2KB] Trouble in retarder oil temperature sensor (rear wheel) system (Disconnection and short circuit)...........................................1174 Failure code [DGR2KZ] Trouble in retarder oil temperature sensor (rear wheel) system (Ground fault)..............................................................1176 Failure code [DGR4KB] Trouble in retarder oil temperature sensor (front wheel) system (Disconnection and short circuit)..........................................1177 Failure code [DGR4KZ] Trouble in retarder oil temperature sensor (front wheel) system (Ground fault).............................................................1178 Failure code [DGR6KX] Steering oil temperature sensor: Input signal out of range.................................................................................1180 Failure code [DGT1KX] Torque converter oil temperature sensor: Out of input signal range.........................................................................1182 Troubleshooting by failure code, Part 7..............................................................................................................................1185 Failure code [DGT5KA] (or VHMS_LED display: "n3" -> "12") Left bank exhaust temperature sensor system (Front): Disconnection.....................................1187 Failure code [dGT5KA] (or VHMS_LED display: "n3" -> "22") Left bank exhaust temperature sensor system (Rear): Disconnection......................................1190 Failure code [DGT5KB] (or VHMS_LED display: "n3" -> "11") Left bank exhaust temperature sensor system (Front): Short circuit....................................1193 Failure code [dGT5KB] (or VHMS_LED display: "n3" -> "21") Left bank exhaust temperature sensor system (Rear): Short circuit......................................1196 Failure code [DGT6KA] (or VHMS_LED display: "n3" -> "24") Right bank exhaust temperature sensor system (Front): Disconnection....................................1199 Failure code [dGT6KA] (or VHMS_LED display: "n3" -> "26") Right bank exhaust temperature sensor system (Rear): Disconnection.....................................1202 Failure code [DGT6KB] (or VHMS_LED display: "n3" -> "23") Right bank exhaust temperature sensor system (Front): Short circuit....................................1205 Failure code [dGT6KB] (or VHMS_LED display: "n3" -> "25") Right bank exhaust temperature sensor system (Rear): Short circuit.....................................1208 Failure code [DHE5KB] or VHMS_LED display: "n3" -> "32" Blow-by pressure sensor: Short circuit...................................................................1211 Failure code [DHE5KY] or VHMS_LED display: "n3" -> "31" Blow-by pressure sensor: Short circuit with power supply line...........................................1214 Failure code [DHP4KY] or VHMS_LED display: "n5" -> "44" Short circuit in suspension pressure sensor system (Front right).........................................1216 Failure code [DHP4KZ] or VHMS_LED display: "n5" -> "43" Disconnectionor ground fault in suspension pressure sensor system(Front right)..........................1218 Failure code [DHP5KY] or VHMS_LED display: "n5" -> "54" Short circuit in suspension pressure sensor system (Front left)..........................................1220 Failure code [DHP5KZ] or VHMS_LED display: "n5" -> "53" Disconnectionor ground fault in suspension pressure sensor system(Front left)............................1222 Failure code [DHP6KA] Suspension pressure sensor system: Disconnection (Right rear)..............................................................................1224 Failure code [DHP6KX] Failure in suspension pressure sensor system trouble: Out of input signal range (Right rear)...............................................1225 Failure code [DHP6KY] or VHMS_LED display: "n5" -> "64" Suspension pressure sensor system: Short circuit (Right rear)............................................1228 Failure code [DHP6KZ] or VHMS_LED display: "n5" -> "63" Suspension pressure sensor system: Disconnection or ground fault (Right rear)............................1230 Failure code [DHP7KA] Suspension pressure sensor system: Disconnection (Left rear)...............................................................................1232 Failure code [DHP7KX] Failure in suspension pressure sensor system trouble: Out of input signal range (Left rear)................................................1233 Failure code [DHP7KY] or VHMS_LED display: "n5" -> "74" Suspension pressure sensor system: Short circuit (Left rear).............................................1236 Failure code [DHP7KZ] or VHMS_LED display: "n5" -> "73" Suspension pressure sensor system: Disconnection or ground fault (Left rear).............................1238 Failure code [DHT5KX] Torque converter oil pressure sensor: Out of input signal range............................................................................1240 Failure code [DHT5L6] Torque converter oil pressure sensor: Disagreement of run and stop condition with signal...................................................1242 Failure code [DHU2KX] Front accumulator oil pressure sensor: Out of input signal range...........................................................................1244 Failure code [DHU3KX] Rear accumulator oil pressure sensor: Out of input signal range............................................................................1246 Failure code [DHU6KX] Trouble in ABS control valve pressure sensor (Front right).................................................................................1248 Failure code [DHU7KX] Trouble in ABS control valve pressure sensor (Front left)..................................................................................1250 Failure code [DHU8KX] Trouble in ABS control valve pressure sensor (Front right).................................................................................1252 Failure code [DHU9KX] Trouble in ABS control valve pressure sensor (Front right).................................................................................1254 Failure code [DJF1KA] Fuel level sensor: Disconnection...........................................................................................................1256 Failure code [DK30KX] Steering angle potentiometer: Trouble (Disconnection)......................................................................................1258 Failure code [DK51L5] Retarder lever potentiometer: Potentiometer signal is inconsistent with swich signal.......................................................1259 Failure code [DK52KX] Failure in hoist lever potentiometer 1: Out of input signal range..........................................................................1262 Failure code [DK53L8] Failure in hoist lever potentiometer 2: Disagreement of analog signal......................................................................1264 Failure code [DK54KX] Body positioner sensor: Out of input signal range..........................................................................................1266 Failure code [DK5VKX] Abnormality of Power Ladder Position Input Signal (Out of Range)...........................................................................1268 Failure code [DK5VMA] Power Ladder System Abnormality............................................................................................................1270 Failure code [DKD0L6] Failure in steering speed sensor...........................................................................................................1272 Failure code [DKH0KX] Clinometer sensor signal out of range......................................................................................................1274 Failure code [DKH1KX] (or VHMS_LED display: "n4"->"33") Abnormality in clinometer sensor.........................................................................1276 Failure code [DLF1KA] Transmission input shaft speed sensor: Disconnection.......................................................................................1278 Failure code [DLF1LC] Transmission input shaft speed sensor: Disagreement of revolution speed signal.............................................................1280 Failure code [DLF2KA] Transmission intermediate shaft speed sensor: Disconnection................................................................................1282 Failure code [DLF2LC] Transmission intermediate shaft speed sensor: Disagreement of revolution speed signal......................................................1284 Troubleshooting by failure code, Part 8..............................................................................................................................1287 Failure code [DLF6KA] Disconnection in wheel speed sensor (Front right)..........................................................................................1290 Failure code [DLF6L3] Trouble in wheel speed sensor (Front right)................................................................................................1292 Failure code [DLF7KA] Disconnection in wheel speed sensor (Front left)...........................................................................................1294 Failure code [DLF7L3] Trouble in wheel speed sensor (Front left).................................................................................................1296 Failure code [DLF8KA] Wheel speed sensor: Disconnection (Rear right).............................................................................................1298 Failure code [DLF8L3] Wheel speed sensor: Disconnection (Rear right).............................................................................................1300 Failure code [DLF8LC] Wheel speed sensor: Trouble (Rear right)...................................................................................................1302 Failure code [DLF8MA] Wheel speed sensor: Disconnection (Rear right).............................................................................................1302 Failure code [DLF9KA] Wheel speed sensor: Disconnection (Rear left)..............................................................................................1304 Failure code [DLF9L3] Wheel speed sensor: Trouble (Rear left)....................................................................................................1306 Failure code [DLF9LC] Wheel speed sensor: Trouble (Rear left)....................................................................................................1308 Failure code [DLF9MA] Wheel speed sensor: Disconnection (Rear left)..............................................................................................1308 Failure code [DLT3KA] Transmission output shaft speed sensor: Disconnection......................................................................................1310 Failure code [DLT3LC] Transmission output shaft speed sensor: Disagreement of revolution speed signal............................................................1312 Failure code [DLT4KA] Transmission output shaft speed sensor: Disconnection......................................................................................1314 Failure code [DLT4MA] Transmission output shaft speed sensor: Disconnection......................................................................................1316 Failure code [DUM7KY] Pre-lubrication operation lamp output abnormality: Hot short circuit.......................................................................1318 Failure code [DUM7KZ] Pre-lubrication operation lamp output abnormality: Disconnection or grounding fault........................................................1320 Failure code [DUM9KZ] Failure of power ladder indicator system...................................................................................................1322 Failure code [DV00KB] Buzzer output: Short circuit...............................................................................................................1324 Failure code [DW2AKA] Main pressure variable valve output: Disconnection.........................................................................................1326 Failure code [DW2AKB] Main pressure variable valve output circuit: Ground fault..................................................................................1328 Failure code [DW2AKY] Main pressure variable valve output circuit: Hot short.....................................................................................1330 Failure code [DW2AL1] Main pressure variable valve: Defective reset..............................................................................................1332 Failure code [DW2ALH] Main pressure variable valve: Malfunction..................................................................................................1334 Failure code [DW2BKA] Main oil level selector valve output: Disconnection........................................................................................1335 Failure code [DW2BKB] Main oil level selector valve output circuit: Ground fault.................................................................................1336 Failure code [DW2BKY] Main oil level selector valve output circuit: Hot short....................................................................................1338 Failure code [DW2BL1] Main oil level selector valve: Defective reset.............................................................................................1340 Failure code [DW2BLH] Main oil level selector valve: Malfunction.................................................................................................1342 Failure code [DW2CKA] Transmission lubrication variable valve output: Disconnection..............................................................................1343 Failure code [DW2CKB] Transmission lubrication variable valve output circuit: Ground fault.......................................................................1344 Failure code [DW2CKY] Transmission lubrication variable valve output circuit: Hot short..........................................................................1346 Failure code [DW2CL1] Transmission lubrication variable valve: Defective reset...................................................................................1348 Failure code [DW2CLH] Transmission lubrication variable valve: Malfunction.......................................................................................1350 Failure code [DW35KZ] Failure in output system of auto suspension solenoid 1: Disconnection or short circuit.....................................................1352 Failure code [DW36KZ] Failure in output system of auto suspension solenoid 2: Disconnection or short circuit.....................................................1354 Failure code [DW71KZ] Exhaust brake output system trouble (Disconection/Ground fault/Hot short)..................................................................1356 Failure code [DW72KZ] Kick-out solenoid output system trouble: Disconnection or short circuit....................................................................1358 Failure code [DW73KZ] Failure in hoist select valve output system: Disconnection or short circuit................................................................1360 Failure code [DW78KZ] Brake cooling valve (BCV) (rear wheel) output system trouble: Disconnection or short circuit...............................................1362 Failure code [DWNBK4] ASR shut-off valve: Trouble (Valve keeps operating)........................................................................................1364 Failure code [DWNBKA] ASR shut-off valve output circuit: Disconnection...........................................................................................1366 Failure code [DWNBKB] ASR shut-off valve output circuit: Ground fault............................................................................................1368 Failure code [DWNBKY] ASR shut-off valve output circuit: Short circuit...........................................................................................1370 Failure code [DWNBMA] ASR shut-off valve: Trouble (Valve does not operate).......................................................................................1371 Failure code [DWNDKZ] Trouble in ABS cut-off valve (Front) system................................................................................................1372 Failure code [DWNDMA] Defective ABS cut-off valve (Front)........................................................................................................1374 Failure code [DWNEKZ] Trouble in ABS cut-off valve (Rear) system.................................................................................................1376 Failure code [DWNEMA] Defective ABS cut-off valve (Rear).........................................................................................................1378 Failure code [DWNLKA] Open Circuit in Power Ladder Shock Reducing Solenoid Output Circuit........................................................................1380 Failure code [DWNLKB] Ground Fault of Power Ladder Shock Reducing Solenoid Output Circuit........................................................................1381 Failure code [DWNLKY] Hot Short in Power Ladder Shock Reducing Solenoid Output Circuit...........................................................................1382 Troubleshooting by failure code, Part 9..............................................................................................................................1385 Failure code [DX11K4] Rear brake proportional pressure reducing solenoid valve: Out of control...................................................................1388 Failure code [DX11KA] Rear brake proportional pressure reducing solenoid valve output circuit: Disconnection.....................................................1390 Failure code [DX11KB] Rear brake proportional pressure reducing solenoid valve: Short circuit....................................................................1391 Failure code [DX11KY] Rear brake proportional pressure reducing solenoid valve: Short circuit to power source line...............................................1392 Failure code [DX11MA] Rear brake proportional pressure reducing solenoid valve: Malfunction......................................................................1394 Failure code [DX12K4] Front brake proportional pressure reducing solenoid valve: Out of control..................................................................1396 Failure code [DX12KA] Front brake proportional pressure reducing solenoid valve output circuit: Disconnection....................................................1398 Failure code [DX12KB] Front brake proportional pressure reducing solenoid valve: Short circuit...................................................................1399 Failure code [DX12KY] Front brake proportional pressure reducing solenoid valve: Short circuit to power source line..............................................1400 Failure code [DX12MA] Front brake proportional pressure reducing solenoid valve: Malfunction.....................................................................1402 Failure code [DX13KA] Output circuit of hoist EPC valve: Disconnection...........................................................................................1404 Failure code [DX13KB] Output circuit of hoist EPC valve: Short circuit...........................................................................................1406 Failure code [DX13KY] Output circuit of hoist EPC valve: Short circuit with power source line....................................................................1408 Failure code [DX17K4] ASR proportional pressure reducing solenoid valve (right): Trouble (Valve keeps operating).................................................1410 Failure code [DX17KA] ASR proportional pressure reducing solenoid valve (right) output circuit: Disconnection....................................................1412 Failure code [DX17KB] ASR proportional pressure reducing solenoid valve (right) output circuit: Ground fault.....................................................1414 Failure code [DX17KY] ASR proportional pressure reducing solenoid valve (right) output circuit: Short circuit....................................................1416 Failure code [DX17MA] ASR proportional pressure reducing solenoid valve (right): Trouble (Valve does not operate)................................................1416 Failure code [DX18K4] ASR proportional pressure reducing solenoid valve (left): Trouble (Valve keeps operating)..................................................1418 Failure code [DX18KA] ASR proportional pressure reducing solenoid valve (left) output circuit: Disconnection.....................................................1420 Failure code [DX18KB] ASR proportional pressure reducing solenoid valve (left) output circuit: Ground fault......................................................1422 Failure code [DX18KY] ASR proportional pressure reducing solenoid valve (left) output circuit: Short circuit.....................................................1424 Failure code [DX18MA] ASR proportional pressure reducing solenoid valve (left): Trouble (Valve does not operate).................................................1424 Failure code [DX21KA] Disconnection in ABS control valve output circuit (Front right)............................................................................1425 Failure code [DX21KB] Ground fault in ABS control valve output circuit (Front right).............................................................................1426 Failure code [DX21KY] Hot short in ABS control valve output circuit (Front right)................................................................................1427 Failure code [DX21MA] Defective ABS control valve (Front right)..................................................................................................1428 Failure code [DX22KA] Disconnection in ABS control valve output circuit (Front left).............................................................................1429 Failure code [DX22KB] Ground fault in ABS control valve output circuit (Front left)..............................................................................1430 Failure code [DX22KY] Hot short in ABS control valve output circuit (Front left).................................................................................1431 Failure code [DX22MA] Defective ABS control valve (Front left)...................................................................................................1432 Failure code [DX23KA] Disconnection in ABS control valve output circuit (Rear right).............................................................................1433 Failure code [DX23KB] Ground fault in ABS control valve output circuit (Rear right)..............................................................................1434 Failure code [DX23KY] Hot short in ABS control valve output circuit (Rear right).................................................................................1435 Failure code [DX23MA] Defective ABS control valve (Rear right)...................................................................................................1436 Failure code [DX24KA] Disconnection in ABS control valve output circuit (Rear left)..............................................................................1437 Failure code [DX24KB] Ground fault in ABS control valve output circuit (Rear left)...............................................................................1438 Failure code [DX24KY] Hot short in ABS control valve output circuit (Rear left)..................................................................................1439 Failure code [DX24MA] Defective ABS control valve (Rear left)....................................................................................................1440 Failure code [DX25MA] Defective ABS front wheel system control valve.............................................................................................1441 Failure code [DX26MA] Defective ABS rear wheel system control valve..............................................................................................1441 Troubleshooting by failure code, Part 10.............................................................................................................................1443 Failure code [DXH1KA] Lockup clutch solenoid output circuit: Disconnection.......................................................................................1446 Failure code [DXH1KB] Lockup clutch solenoid output circuit: Short circuit.......................................................................................1448 Failure code [DXH1KY] Lockup clutch solenoid output circuit: Short circuit to power supply line..................................................................1450 Failure code [DXH2KA] Hi clutch solenoid output circuit: Disconnection...........................................................................................1452 Failure code [DXH2KB] Hi clutch solenoid output circuit: Short circuit...........................................................................................1454 Failure code [DXH2KY] Hi clutch solenoid output circuit: Short circuit to power supply line......................................................................1456 Failure code [DXH3KA] Lo clutch solenoid output circuit: Disconnection...........................................................................................1460 Failure code [DXH3KB] Lo clutch solenoid output circuit: Short circuit...........................................................................................1462 Failure code [DXH3KY] Lo clutch solenoid output circuit: Short circuit in power supply line......................................................................1464 Failure code [DXH4KA] 1st clutch solenoid output circuit: Disconnection..........................................................................................1468 Failure code [DXH4KB] 1st clutch solenoid output circuit: Short circuit..........................................................................................1470 Failure code [DXH4KY] 1st clutch solenoid output circuit: Short circuit to power supply line.....................................................................1472 Failure code [DXH5KA] 2nd clutch solenoid output circuit: Disconnection..........................................................................................1476 Failure code [DXH5KB] 2nd clutch solenoid output circuit: Short circuit..........................................................................................1478 Failure code [DXH5KY] 2nd clutch solenoid output circuit: Short circuit in power supply line.....................................................................1480 Failure code [DXH6KA] 3rd clutch solenoid output circuit: Disconnection..........................................................................................1484 Failure code [DXH6KB] 3rd clutch solenoid output circuit: Short circuit..........................................................................................1486 Failure code [DXH6KY] 3rd clutch solenoid output circuit: Short circuit to power supply line.....................................................................1488 Failure code [DXH7KA] R clutch solenoid output circuit: Disconnection............................................................................................1492 Failure code [DXH7KB] R clutch solenoid output circuit: Short circuit............................................................................................1494 Failure code [DXH7KY] R clutch solenoid output circuit: Short circuit to power supply line.......................................................................1496 Failure code [DXHHKA] 4th clutch solenoid output circuit: Disconnection..........................................................................................1498 Failure code [DXHHKB] 4th clutch solenoid output circuit: Short circuit..........................................................................................1500 Failure code [DXHHKY] 4th clutch solenoid output circuit: Short circuit to power supply line.....................................................................1502 Failure code [F@BBZL] or VHMS_LED display: "n3" -> "38" Blow-by pressure: High error.............................................................................1505 Failure code [F@BYNS] (or VHMS_LED display "n3" -> "61") Left front exhaust temperature sensor (1): Exhaust temperature abnormal rise............................1506 Failure code [f@BYNS] (or VHMS_LED display "n3" -> "71") Left rear exhaust temperature sensor (1): Exhaust temperature abnormal rise.............................1508 Failure code [F@BZNS] (or VHMS_LED display "n3" -> "81") Right front exhaust temperature sensor (1): Exhaust temperature abnormal rise...........................1510 Failure code [f@BZNS] (or VHMS_LED display "n3" -> "91") Right rear exhaust temperature sensor (1): Exhaust temperature abnormal rise............................1512 Troubleshooting of electrical system (E-mode)........................................................................................................................1523 Before troubleshooting of electric system........................................................................................................................1525 Contents of troubleshooting table................................................................................................................................1526 E-1 Engine does not start........................................................................................................................................1527 E-2 Automatic preheating does not operate........................................................................................................................1530 E-3 Machine monitor does not display all, when starting switch is turned ON......................................................................................1534 E-4 Machine monitor does not operate when starting switch is OFF.................................................................................................1536 E-5 Alarm buzzer does not sound..................................................................................................................................1538 E-6 Alarm buzzer does not stop sounding..........................................................................................................................1540 E-7 Gauges of machine monitor, caution lamps or character display section do not display properly................................................................1541 E-8 A selection of the display in character display section cannot be changed....................................................................................1543 E-9 Power mode selecting function does not operate properly......................................................................................................1546 E-10 AISS function does not operate properly.....................................................................................................................1547 E-11 Seat belt caution lamp does not display properly............................................................................................................1548 E-12 Turn signal lamp or turning lamp (hazard lamp) do not work properly.........................................................................................1549 E-13 Night illumination (lighting) does not work properly........................................................................................................1552 E-14 Emergency steering does not operate.........................................................................................................................1564 E-15 Hoist lever does not operate normally.......................................................................................................................1569 E-16 Power supply system (Air conditioner does not operate)......................................................................................................1572 E-17 Compressor and refrigerant system (Air is not cooled).......................................................................................................1574 E-18 Blower motor system (Air does not come out or air flow is abnormal).........................................................................................1576 E-19 Ladder cannot be lowered with operation switch outside cab..................................................................................................1578 E-20 Ladder cannot be lowered with operation switch inside cab...................................................................................................1579 E-21 Ladder continues lowering...................................................................................................................................1580 E-22 Ladder cannot be raised with operation switch outside cab...................................................................................................1581 E-23 Ladder cannot be lowered with operation switch inside cab...................................................................................................1582 E-24 Ladder continues rising.....................................................................................................................................1583 E-25 Buzzer does not sound when power ladder is operated.........................................................................................................1584 E-26 Power ladder pump does not operate..........................................................................................................................1585 Troubleshooting of hydraulic and mechanical system (H-mode)..........................................................................................................1587 Contents of troubleshooting table................................................................................................................................1589 H-1 Machine does not start.......................................................................................................................................1590 H-2 Machine does not travel smoothly (hunting)...................................................................................................................1592 H-3 Lockup cannot be cancelled...................................................................................................................................1592 H-4 Excessive shock when starting or shifting excessive..........................................................................................................1593 H-5 Transmission does not shift up...............................................................................................................................1594 H-6 Machine lacks power or speed when traveling..................................................................................................................1596 H-7 Time lag is excessive when starting or shifting gear.........................................................................................................1600 H-8 Torque converter oil temperature is high.....................................................................................................................1602 H-9 Torque converter oil pressure is low.........................................................................................................................1603 H-10 Front brake is ineffective..................................................................................................................................1604 H-11 Rear brake is ineffective...................................................................................................................................1605 H-12 Steering wheel is heavy.....................................................................................................................................1606 H-13 Steering wheel does not work................................................................................................................................1607 H-14 Steering wheel vibrates.....................................................................................................................................1608 H-15 Dump body lifting speed is slow.............................................................................................................................1609 H-16 Dump body does not work.....................................................................................................................................1610 H-17 Excessive hydraulic drift of dump body......................................................................................................................1611 H-18 Power ladder does not move or its speed is low..............................................................................................................1612 Troubleshooting of engine (S-mode)...................................................................................................................................1615 Method of using troubleshooting charts...........................................................................................................................1617 S-1 Starting performance is poor1................................................................................................................................1620 S-2 Engine does not start........................................................................................................................................1621 S-3 Engine does not pick up smoothly.............................................................................................................................1624 S-4 Engine stops during operations...............................................................................................................................1625 S-5 Engine does not rotate smoothly..............................................................................................................................1626 S-6 Engine lacks output (or lacks power).........................................................................................................................1627 S-7 Exhaust smoke is black (incomplete combustion)...............................................................................................................1629 S-8 Oil consumption is excessive (or exhaust smoke is blue)......................................................................................................1630 S-9 Oil becomes contaminated quickly.............................................................................................................................1631 S-10 Fuel consumption is excessive...............................................................................................................................1632 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1......................................................................................1633 S-12 Oil pressure drops..........................................................................................................................................1634 S-13 Oil level rises (Entry of coolant or fuel)..................................................................................................................1635 S-14 Coolant temperature becomes too high (overheating)..........................................................................................................1636 S-15 Abnormal noise is made......................................................................................................................................1637 S-16 Vibration is excessive......................................................................................................................................1638 50 Disassembly and assembly.............................................................................................................................................. 0 General information on disassembly and assembly......................................................................................................................1641 How to read this manual..........................................................................................................................................1642 Coating materials list...........................................................................................................................................1644 Special tool list................................................................................................................................................1647 Sketches of special tools........................................................................................................................................1650 Engine and cooling system............................................................................................................................................1657 Removal and installation of fuel supply pump assembly............................................................................................................1658 Removal and installation of fuel injector assembly...............................................................................................................1660 Removal and installation of cylinder head assembly...............................................................................................................1661 Removal and installation of engine hood assembly.................................................................................................................1674 Removal and installation of radiator assembly....................................................................................................................1675 Removal and installation of engine assembly......................................................................................................................1684 Removal and installation of engine front oil seal................................................................................................................1689 Removal and installation of engine rear oil seal.................................................................................................................1692 Power train, Part 1..................................................................................................................................................1697 Removal and installation of front drive shaft....................................................................................................................1698 Removal and installation of rear drive shaft.....................................................................................................................1700 Removal and installation of output shaft assembly................................................................................................................1701 Disassembly and assembly of damper assembly......................................................................................................................1706 Removal and installation of torque converter and transmission assembly...........................................................................................1708 Disconnection and connection of torque converter assembly and transmission assembly..............................................................................1711 Disassembly and assembly of torque converter PTO assembly........................................................................................................1718 Disassembly and assembly of transmission assembly................................................................................................................1731 Power train, Part 2..................................................................................................................................................1765 Removal and installation of final drive carrier assembly.........................................................................................................1766 Disassembly and assembly of final drive carrier assembly.........................................................................................................1768 Removal and installation of differential assembly................................................................................................................1770 Disassembly and assembly of differential assembly................................................................................................................1773 Steering system......................................................................................................................................................1787 Removal and installation of steering cylinder assembly...........................................................................................................1788 Disassembly and assembly of steering cylinder assembly...........................................................................................................1789 Removal and installation of steering valve assembly..............................................................................................................1793 Disassembly and assembly of steering valve assembly..............................................................................................................1794 Brake system.........................................................................................................................................................1807 Removal and installation of front wheel hub and brake assembly...................................................................................................1808 Disassembly and assembly of front wheel hub and brake assembly...................................................................................................1812 Removal and installation of final drive and rear brake assembly..................................................................................................1820 Disassembly and assembly of final drive and rear brake assembly..................................................................................................1822 Undercarriage and frame..............................................................................................................................................1837 Removal and installation of front wheel assembly.................................................................................................................1838 Removal and installation of rear wheel assembly..................................................................................................................1840 Removal and installation of front suspension cylinder assembly...................................................................................................1842 Disassembly and assembly of front suspension cylinder assembly (cylinder with buffer ring).......................................................................1844 Removal and installation of king pin.............................................................................................................................1847 Removal and installation of rear suspension cylinder assembly....................................................................................................1849 Disassembly and assembly of rear suspension cylinder assembly....................................................................................................1850 Hydraulic system.....................................................................................................................................................1855 Removal and installation of hoist valve assembly.................................................................................................................1856 Disassembly and assembly of hoist valve assembly.................................................................................................................1857 Disassembly and assembly of hoist cylinder assembly..............................................................................................................1859 Body.................................................................................................................................................................1867 Removal and installation of body assembly........................................................................................................................1868 Cab and its attachments..............................................................................................................................................1873 Disassembly and assembly of operator's seat assembly.............................................................................................................1874 Removal and installation of air conditioner unit assembly........................................................................................................1884 Electrical system....................................................................................................................................................1887 Removal and installation of engine controller assembly...........................................................................................................1888 Removal and installation of transmission controller assembly.....................................................................................................1888 Removal and installation of retarder controller assembly.........................................................................................................1889 Removal and installation of ABS controller assembly..............................................................................................................1889 Removal and installation of VHMS controller assembly.............................................................................................................1890 90 Diagrams and drawings................................................................................................................................................. 0 Hydraulic diagrams and drawings......................................................................................................................................1893 Power train hydraulic circuit diagram............................................................................................................................1895 Steering and hoist hydraulic circuit diagram.....................................................................................................................1896 Brake hydraulic circuit diagram..................................................................................................................................1897 Brake hydraulic circuit diagram (ASR specification)..............................................................................................................1898 Brake hydraulic circuit diagram (ABS specification)..............................................................................................................1899 Brake hydraulic circuit diagram (ASR and ABS specification)......................................................................................................1900 Hydraulic circuit diagram for power ladder.......................................................................................................................1901 Electrical diagrams and drawings.....................................................................................................................................1903 Electrical circuit diagram for outside cab.......................................................................................................................1905 Electrical circuit diagram for inside cab........................................................................................................................1909 Electrical circuit diagram for ABS (Outside cab) (If equipped)...................................................................................................1917 Electrical circuit diagram for ABS (Inside cab) (If equipped)....................................................................................................1918 Electrical circuit diagram for ASR (If equipped).................................................................................................................1919 Electrical circuit diagram for power ladder......................................................................................................................1920 Air conditioner electrical circuit diagram.......................................................................................................................1921 Electrical circuit diagram for auto greasing (If equipped).......................................................................................................1922 Electrical circuit diagram of external power supply heater.......................................................................................................1923
KOMATSU HD785-7 DUMP TRUCK SHOP MANUAL SEN05900-01 – PDF DOWNLOAD:
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