Komatsu WHEEL LOADER HD785-7 Shop Manual SEN05476-14 – PDF DOWNLOAD

Description

Komatsu WHEEL LOADER HD785-7 Shop Manual SEN05476-14 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WHEEL LOADER HD785-7 Shop Manual SEN05476-14 – PDF DOWNLOAD

Language : English
Pages :1950
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu WHEEL LOADER HD785-7 Shop Manual SEN05476-14 – PDF DOWNLOAD

SERIAL NUMBERS 8393 and up

1. General precautions

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

TABLE OF CONTENTS:

Komatsu WHEEL LOADER HD785-7 Shop Manual SEN05476-14 – PDF DOWNLOAD

SERIAL NUMBERS 8393 and up

Cover 1
00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword and general information 23
Safety notice 24
How to read the shop manual 30
Explanation of terms for maintenance standard 32
Handling of electric equipment and hydraulic component 34
Handling of connectors newly used for engines 43
How to read electric wire code 46
Precautions when carrying out operation 49
Method of disassembling and connecting push-pull type coupler 52
Standard tightening torque table 55
Conversion table 59
01 Specification 65
Specification and technical data 65
Specification drawing 66
Specifications 67
Weight table 70
Fuel, coolant and lubricants 71
10 Structure, function and maintenance standard 75
Engine and cooling system 75
Radiator, brake, torque converter oil cooler, aftercooler, steering, hoist oil cooler 76
Fuel system 78
Power train, Part 1 81
Power train skeleton 82
Output shaft 84
Drive shaft 86
Torque converter and transmission hydraulic piping 88
Torque converter 90
Torque converter valve 98
Transmission 101
Transmission control valve 129
ECMV 131
Lubricating oil amount selector valve 138
Power train, Part 2 141
Axle 142
Differential 144
Final drive 145
Wheels 146
Steering system 149
Steering column 150
Steering linkage 151
Brake system 155
Brake piping 156
Brake valve 158
Secondary brake valve 161
Accumulator charge valve 162
Accumulator 166
Slack adjuster 168
Brake, parking brake 172
Parking brake solenoid 178
Retarder control valve 179
Exhaust brake 180
Undercarriage and frame 183
Suspension 184
Suspension cylinder 186
Rear axle support 194
Hydraulic system 197
Steering and hoist hydraulic piping 198
Steering, hoist filter (high pressure circuit) 200
Dump body control 202
Hydraulic tank 204
Steering valve 205
Crossover relief valve 209
Steering cylinder 210
Steering control valve 211
Hoist valve 220
Dump control valve (EPC valve) 226
Hydraulic pump 230
Work equipment (Body) 235
Auto greasing system 236
Buddy system (if equipped) 247
Hoist cylinder 249
Cab and its attachments 251
ROPS cab 252
Air conditioner 253
Rear view monitor 263
Controller related 266
Electrical system, Part 1 269
Machine monitor system 270
Electrical system, Part 2 295
Automatic shift control system 296
External power supply heater 316
Engine, transmission, hydraulic tank and brake sub-tank heater 318
Automatic emergency steering system 319
Retarder control system 323
Battery disconnector switch 336
Dump control lever 339
Electrical system, Part 3 345
VHMS controller related 346
ASR system (If equipped) 372
Altitude setting function 382
Electrical system, Part 4 387
Sensors, switches 388
20 Standard value table 405
Standard service value table 405
Standard value table for engine 406
Standard value table for machine 408
30 Testing and adjusting 421
Testing and adjusting, Part 1 421
Precautions before work 423
Testing and adjusting tools list 424
Sketch of special tool 430
Testing engine speed 431
Testing air supply pressure (boost pressure) 432
Testing exhaust temperature 434
Testing exhaust gas color 436
Adjustment of valve clearance 438
Testing compression pressure 440
Testing blow-by pressure 442
Testing engine oil pressure 443
Handling of fuel system devices 444
Releasing residual pressure from fuel system 444
Testing fuel pressure 445
Reduced cylinder mode operation 446
No-injection cranking 446
Testing leakage-from pressure limiter and return rate from injector 447
Bleeding air from fuel circuit (Standard spec) 450
Bleeding air from fuel circuit (Extra low-grade fuel spec) 452
Testing the fuel circuit for leakage 454
Replacement and adjustment of fan belt 455
Testing and adjusting alternator belt tension 456
Testing and adjusting air conditioner compressor belt 457
Handling external power source type electric heater 458
Testing and adjusting, Part 2 463
Testing torque converter stall speed 465
Testing power train oil pressure 467
Adjusting transmission speed sensor 475
Testing and adjusting brake oil pressure 476
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas 479
Testing brake performance 487
Releasing remaining pressure in brake circuit 489
Bleeding air from brake circuit 490
Bleeding air from ASR circuit (if equipped) 492
Testing wear of front brake disc 493
Testing wear of rear brake disc 494
Method of releasing parking brake in an emergency 495
Testing and adjusting front suspension cylinder 496
Testing and adjusting rear suspension cylinder 500
Testing and adjusting front suspension cylinder (Automatic suspension specification) 504
Testing and adjusting hydraulic pressure in steering, hoist circuit 505
Testing and adjusting oil pressure in dump EPC circuit 508
Air bleeding from steering cylinder 509
Procedure for raising dump body in emergency 510
How to dump load from failed machine by using buddy system (if equipped) 511
Adjusting body positioner sensor 514
Resetting method for dump body seating control 516
Adjustment of tilt lock lever of steering wheel 517
Handling of high voltage circuit of engine controller 518
Adjusting transmission controller 518
Method for emergency escape at electrical system failure 519
Testing and adjusting, Part 3 525
Setting and adjusting of devices 526
Testing and adjusting, Part 4 541
Special functions of machine monitor (EMMS) 542
Testing and adjusting, Part 5 611
Opening ORBCOMM terminal 612
VHMS controller initial setting procedure (Setting method with VHMS tool) 614
VHMS controller initial setting procedure (Setting method with KOMTRAX Plus PC tool) 639
Download data from VHMS controller (Download method with KOMTRAX Plus PC tool) 641
Precautions for replacing VHMS controller 643
Pm Clinic check sheet 649
Initial setting of payload meter 653
Setting of payload meter built in VHMS 654
40 Troubleshooting 663
Failure code table and fuse locations 663
Failure codes table 664
Fuse locations 681
General information on troubleshooting 687
Precautions before work 688
Points to remember when troubleshooting 689
Sequence of events in troubleshooting 690
Check before troubleshooting 691
Classification and procedures for troubleshooting 692
Contents of troubleshooting table 693
Connection table for connector pin numbers 695
T- branch box and T- branch adapter table 731
Troubleshooting by failure code, Part 1 735
Failure code [1500L0] Dual engagement 737
Failure code [15B0NX] Transmission oil filter: Clogging 738
Failure code [15F0KM] R → F shifting abuse 1: Mistake in operation 740
Failure code [15F0MB] R → F shifting abuse 2: Mistake in operation 740
Failure code [15F7KM] Forward clutch disk abuse: Mistake in operation or setting 741
Failure code [15G0MW] R clutch: Slipping 742
Failure code [15G7KM] Reverse clutch disk abuse: Mistake in operation or setting 744
Failure code [15H0MW] Hi clutch: Slipping 746
Failure code [15J0MW] Lo clutch: Slipping 748
Failure code [15K0MW] 1st clutch: Slipping 750
Failure code [15L0MW] 2nd clutch: Slipping 752
Failure code [15M0MW] 3rd clutch: Slipping 754
Failure code [15N0MW] 4th clutch: Slipping 756
Failure code [15SBL1] R clutch solenoid: Fill signal is ON when command current is OFF 758
Failure code [15SBMA] R clutch solenoid: Malfunction 760
Failure code [15SCL1] Hi clutch solenoid: Fill signal is ON when command current is OFF 762
Failure code [15SCMA] Hi clutch solenoid: Malfunction 766
Failure code [15SDL1] Lo clutch solenoid: Fill signal is ON when command current is OFF 768
Failure code [15SDMA] Lo clutch solenoid: Malfunction 772
Failure code [15SEL1] 1st clutch solenoid: Fill signal is ON when command current is OFF 774
Failure code [15SEMA] 1st clutch solenoid: Malfunction 778
Troubleshooting by failure code, Part 2 781
Failure code [15SFL1] 2nd clutch solenoid: Fill signal is ON when command current is OFF 783
Failure code [15SFMA] 2nd clutch solenoid: Malfunction 786
Failure code [15SGL1] 3rd clutch solenoid: Fill signal is ON when command current is OFF 788
Failure code [15SGMA] 3rd clutch solenoid: Malfunction 792
Failure code [15SHL1] 4th clutch solenoid: Fill signal is ON when command current is OFF 794
Failure code [15SHMA] 4th clutch solenoid: Malfunction 798
Failure code [15SJMA] Lockup clutch solenoid: Malfunction 800
Failure code [2F00KM] Parking brake: Mistake in operation or setting 801
Failure code [2G42ZG] Accumulator: Oil pressure reduction (Front) 804
Failure code [2G43ZG] Accumulator: Oil pressure reduction (Rear) 804
Failure code [989A00] Engine over run prevention command signal: Operating 805
Failure code [989D00] Rear section tipping over alarm: Alarm is activated 805
Failure code [A570NX] Engine oil filter: Clogging 806
Failure code [AA10NX] Air cleaner element: Clogging 808
Failure code [AB00L4] Alternator: Failure on battery charge circuit (R terminal signal is present and engine is stopped) 810
Failure code [AB00MA] Alternator: Malfunction 812
Failure code [AB00MB] Alternator: Failure on battery charge circuit (Absence of R terminal signal and detection error) 814
Failure code [B@BAZG] Abnormal lowering of engine oil pressure: Lowering of oil pressure 816
Failure code [B@BAZK] Engine oil: Level too low 818
Failure code [B@BCNS] Engine: Overheat 820
Failure code [B@BCZK] Lowering of radiator coolant: Lowering of level 822
Failure code [B@BFZK] Lowering of fuel level 824
Failure code [B@C6NS] Brake cooling oil: Overheating (Front) 826
Failure code [B@C7NS] Brake cooling oil: Overheating (Rear) 827
Failure code [B@CENS] Overheating of torque converter oil 828
Failure code [B@GAZK] Battery electrolyte level: Lowering of level 829
Failure code [B@JANS] Steering oil: Overheat 830
Troubleshooting by failure code, Part 3 833
Failure code [CA111] Engine controller (Left bank): Internal abnormality 836
Failure code [CB111] Engine controller (Right bank): Internal abnormality 838
Failure code [CA115] Abnormal engine Ne and Bkup speed sensors (Left bank): Abnormal speed sensor signal 840
Failure code [CB115] Abnormal engine Ne and Bkup speed sensors (Right bank): Abnormal speed sensor signal 841
Failure code [CA122] Charge pressure sensor too high (At left bank only): Excessively high voltage detected 842
Failure code [CA123] Charge pressure sensor too low (At left bank only): Excessively low voltage detected 844
Failure code [CA131] Throttle sensor high error (At left bank only) 846
Failure code [CA132] Throttle sensor low error (At left bank only) 849
Failure code [CA135] Oil pressure sensor too high (At left bank only): Excessively high voltage detected 850
Failure code [CA141] Oil pressure sensor too low (At left bank only): Excessively low voltage detected 852
Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected 854
Failure code [CA145] Coolant temperature sensor too low (At left bank only): Excessively low voltage detected 856
Failure code [CA153] Charge temperature sensor too high (At left bank only): Excessively high voltage detected 858
Failure code [CA154] Charge temperature sensor too low (At left bank only): Excessively low voltage detected 860
Failure code [CA187] Sensor power supply (2) abnormally low level (Left bank): Low voltage detection 862
Failure code [CB187] Sensor power supply (2) abnormally low level (Right bank): Low voltage detection 862
Failure code [CA212] Engine oil temperature sensor abnormally high level (At left bank only): High voltage detection 864
Failure code [CA213] Engine oil temperature sensor abnormally lowlevel (At left bank only): Low voltage detection 866
Failure code [CA221] Atmospheric pressure sensor too high (At left bank only): Excessively high voltage detected 868
Failure code [CA222] Atmospheric pressure sensor too low (At left bank only): Excessively low voltage detected 870
Failure code [CA227] Sensor power source (2) too high (Left bank): Excessively high voltage detected 872
Failure code [CB227] Sensor power supply (2) abnormally high level (Right bank): High voltage detection 874
Failure code [CA234] Engine over speed (At left bank only): Excessively high speed 876
Failure code [CA238] Abnormal power source for Ne speed sensor (At left bank only): Excessively low voltage detected 878
Failure code [CB238] Abnormal power source for Ne speed sensor (At right bank only): Excessively low voltage detected 880
Failure code [CA263] Fuel temperature sensor too high (Left bank): Excessively high voltage detected 882
Failure code [CB263] Fuel temperature sensor too high (Right bank): Excessively high voltage detected 884
Failure code [CA265] Fuel temperature sensor abnormally low level (Left bank): Low voltage detection 886
Failure code [CB265] Fuel temperature sensor abnormally low level (Right bank): Low voltage detection 886
Failure code [CA271] PCV1 short circuit (Left bank): Short circuit 887
Failure code [CB271] PCV1 short circuit (Right bank): Short circuit 888
Failure code [CA272] PCV1 disconnection (Left bank): Disconnection 889
Failure code [CB272] PCV1 disconnection (Right bank): Disconnection 890
Failure code [CA273] PCV2 short circuit (Left bank): Short circuit 891
Failure code [CB273] PCV2 short circuit (Right bank): Short circuit 892
Failure code [CA274] PCV2 disconnection (Left bank): Disconnection 893
Failure code [CB274] PCV2 disconnection (Right bank): Disconnection 894
Troubleshooting by failure code, Part 4 897
Failure code [CA322] Injector No 1 (L/B No1) system disconnection or short circuit (Left bank): Disconnection, short circuit 900
Failure code [CA323] Injector No 5 (L/B No5) system disconnection or short circuit (Left bank): Disconnection, short circuit 902
Failure code [CA324] Injector No 3 (L/B No3) system disconnection or short circuit (Left bank): Disconnection, short circuit 904
Failure code [CA325] Injector No 6 (L/B No6) system disconnection or short circuit (Left bank): Disconnection, short circuit 906
Failure code [CA331] Injector No 2 (L/B No2) system disconnection or short circuit (Left bank): Disconnection, short circuit 908
Failure code [CA332] Injector No 4 (L/B No4) system disconnection or short circuit (Left bank): Disconnection, short circuit 910
Failure code [CA342] Engine controller data mismatch (Left bank): Mismatch 912
Failure code [CB342] Engine controller data mismatch (Right bank): Mismatch 912
Failure code [CA351] Abnormal injector drive circuit (Left bank): Abnormal circuit 914
Failure code [CB351] Injector drive circuit abnormality (Right bank): Circuit abnormality 916
Failure code [CA352] Sensor power supply (1) abnormally low level (Left bank): Low voltage detection 918
Failure code [CB352] Sensor power supply (1) abnormally low level (Right bank): Low voltage detection 918
Failure code [CA386] Sensor power supply (1) abnormally high level (Left bank): High voltage detection 920
Failure code [CB386] Sensor power supply (1) abnormally high level (Right bank): High voltage detection 922
Failure code [CA431] Trouble in idle validation switch 924
Failure code [CA432] Idle validation action error 928
Failure code [CA441] Power supply voltage abnormally low level (Left bank): Low voltage detection 929
Failure code [CB441] Power supply voltage abnormally low level (Right bank): Low voltage detection 929
Failure code [CA442] Power supply voltage abnormally high level (Left bank): High voltage detection 930
Failure code [CB442] Power supply voltage abnormally high level (Right bank): High voltage detection 930
Failure code [CA449] Common rail abnormally high pressure (2) (Left bank): Abnormally high pressure occurrence 931
Failure code [CB449] Common rail abnormally high pressure (2) (Right bank): Abnormally high pressure occurrence 931
Failure code [CA451] Common rail pressure sensor too high (Left bank): Excessively high voltage detected 932
Failure code [CB451] Common rail pressure sensor abnormally high level (Right bank): High voltage detection 934
Failure code [CA452] Common rail pressure sensor abnormally low level (Left bank): Abnormally low voltage detection 936
Failure code [CB452] Common rail pressure sensor abnormally low level (Right bank): Abnormally low voltage detection 936
Failure code [CA553] Common rail pressure too high (1) (Left bank): Excessively high pressure detected 937
Failure code [CB553] Common rail pressure too high (1) (Right bank): Excessively high pressure detected 938
Failure code [CA554] In-range error in common rail pressure sensor (Left bank): In-range error 939
Failure code [CB554] In-range error in common rail pressure sensor (Right bank): In-range error 939
Failure code [CA559] Loss of pressure feed from supply pump (1) (Left bank): Loss of pressure feed detected 940
Failure code [CB559] Loss of pressure feed from supply pump (1) (Right bank): Loss of pressure feed detected 944
Failure code [CA689] Abnormal engine Ne speed sensor (Left bank): Abnormal signal 948
Failure code [CB689] Abnormal engine Ne speed sensor (Right bank): Abnormal signal 950
Failure code [CA691] Intake air temperature sensor abnormally high level (At left bank only): High voltage detection 952
Failure code [CA692] Intake air temperature sensor abnormally low level (At left bank only): Low voltage detection 954
Failure code [CA731] Abnormal engine Bkup speed sensor phase (Left bank): Abnormal phase 955
Failure code [CB731] Abnormal engine Bkup speed sensor phase (Right bank): Abnormal phase 955
Troubleshooting by failure code, Part 5 957
Failure code [CA757] Loss of all engine controller data (Left bank): Loss of all data 959
Failure code [CB757] Loss of all engine controller data (Right bank): Loss of all data 959
Failure code [CA778] Abnormal engine Bkup speed sensor (Left bank): Abnormal Bkup signal 960
Failure code [CB778] Engine Bkup speed sensor abnormality (Right bank): Bkup signal error 962
Failure code [CA781] Inter-multicontroller communication error (Left bank): Communication error 964
Failure code [CB781] Inter-multicontroller communication error (Right bank): Communication error 966
Failure code [CA1257] Multicontroller distinction wiring harness key error (Left bank): Distinction error 967
Failure code [CB1257] Multicontroller distinction wiring harness key error (Right bank): Distinction error 968
Failure code [CB1548] Injector #7 (R/B #1) system disconnection/short circuit (Right bank): Disconnection/Short circuit 970
Failure code [CB1549] Injector #8 (R/B #2) system disconnection/short circuit (Right bank): Disconnection/Short circuit 972
Failure code [CB1551] Injector #10 (R/B #4) system disconnection/short circuit (Right bank): Disconnection/Short circuit 974
Failure code [CB1552] Injector #11 (R/B #5) system disconnection/short circuit (Right bank): Disconnection/Short circuit 976
Failure code [CB1553] Injector #12 (R/B #6) system disconnection/short circuit (Right bank): Disconnection/Short circuit 978
Failure code [CB1622] Injector #9 (R/B #3) system disconnection/short circuit (Right bank): Disconnection/Short circuit 980
Failure code [CA1633] KOMNET abnormality (Left bank): Communication error 982
Failure code [CA2185] Throttle sensor supply voltage high error 984
Failure code [CA2186] Throttle sensor power supply low error 986
Failure code [CA2249] Loss of pressure feed from supply pump (2) (Left bank): Loss of pressure feed detected 987
Failure code [CA2555] Intake heater relay voltage low error (Left bank) 988
Failure code [CA2556] Intake heater relay voltage high error (Left bank) 990
Troubleshooting by failure code, Part 6 993
Failure code [D180KA] Preheating relay output system: Disconnection 996
Failure code [D180KB] Preheating relay output system: Grounding fault 997
Failure code [D180KY] Preheating relay output system: Hot short circuit 998
Failure code [D19HKB] Stop lamp relay output system: Short circuit1000
Failure code [D1EFKA] Pre-lubrication start relay output system: Disconnection1002
Failure code [D1EFKB] Pre-lubrication start relay output system: Grounding fault1004
Failure code [D1EFKY] Pre-lubrication start relay output system: Hot short circuit1006
Failure code [D1EHKA] Engine start relay output system: Disconnection1008
Failure code [D1EHKB] Engine start relay output system: Grounding fault1010
Failure code [D1EHKY] Engine start relay output system: Hot short circuit1012
Failure code [DAF9KM] Wrong connection of connector1014
Failure code [DAFRKR] Abnormal CAN communication (machine monitor): Abnormal communication1015
Failure code [DAQ0KK] Transmission controller direct power supply: Lowering of power supply voltage1016
Failure code [DAQ0KT] Transmission controller nonvolatile memory: Abnormality in controller1018
Failure code [DAQ2KK] Transmission controller solenoid power supply: Power supply voltage too low1020
Failure code [DAQ9KQ] Transmission controller: Disagreement of model selection1022
Failure code [DAQRKR] Abnormality in CAN communication (Transmission)1023
Failure code [DAQRMA] Transmission controller option setting: Malfunction1028
Failure code [DAQV00] Neutral coast prevention control actuation caution: Caution actuated1029
Failure code [DAQW00] Neutral coast state caution: Caution actuated1030
Failure code [DB10KT] Retarder controller nonvolatile memory: Abnormality in controller1031
Failure code [DB12KK] Retarder controller solenoid power supply: Power supply system trouble1032
Failure code [DB13KK] Retarder controller battery direct power supply: Power supply voltage too low1034
Failure code [DB19KQ] Disagreement of model selection (Retarder controller)1036
Failure code [DB1RKR] CAN communication (retarder controller): Communication disabled1038
Failure code [DB1RMA] Disagreement of option setting (Retarder controller)1042
Failure code [DB2RKR] CAN communication (engine controller): Communication disabled1043
Failure code [dB2RKR] CAN communication (engine controller): Communication disabled1049
Failure code [DBB0KK] or VHMS_LED display: “n9” → “01”1056
Failure code [DBB0KQ] (or VHMS_LED display: “nF” → “11”) VHMS controller: Disagreement of model selection signals1058
Failure code [DBB3KK] (or VHMS_LED display: “n9” → “05”) VHMS controller battery power supply: Low power supply voltage (input)1060
Failure code [DBB5KP] (or VHMS_LED display: “n9” → “04”) VHMS controller 5 V power supply output: Low output voltage1062
Failure code [DBB6KP] (or VHMS_LED display: “n9” → “02”) VHMS controller 24 V power supply output: Low output voltage1064
Failure code [DBB7KP] (or VHMS_LED display: “n9” → “03”) VHMS controller 12 V power supply output: Low output voltage1066
Failure code [DBBQKR] (or VHMS_LED display: “n8” → “02”) VHMS controller CAN communication: Defective communication (Abnormality in target component system)1067
Failure code [DBBRKR] Abnormality in CAN communication (VHMS)1067
Failure code [DBC9KQ] Disagreement of model selection (ABS controller)1068
Failure code [DBCRKR] Abnormality in CAN communication (ABS)1069
Failure code [DBCRMA] Disagreement of option setting (ABS controller)1073
Failure code [DBG2KK] Solenoid power supply: Low voltage1074
Failure code [DBG3KK] Battery direct power supply: Low voltage1076
Failure code [DBG9KQ] Model selection signal: Abnormal1078
Failure code [DDD7KX] Trouble in travel speed setting switch system: Out of input signal range1080
Failure code [DDD8KA] ARSC system switch system: Disconnection (If equipped)1082
Failure code [DDD8KB] ARSC system switch system: Short circuit (If equipped)1084
Failure code [DDD9KA] ABS system switch system: Disconnection1086
Failure code [DDD9KB] ABS system switch system: Short circuit1088
Failure code [DDDAKA] ASR system switch: Disconnection1090
Failure code [DDDAKB] ASR system switch: Short circuit1092
Failure code [DDE2KB] Engine oil pressure switch error: Grounding fault1094
Failure code [DDE2L6] Engine oil pressure switch error: Disconnection or hot short circuit1096
Failure code [DDP6L4] Service brake pressure switch trouble (Rear)1098
Failure code [DDTHKA] Hi clutch fill switch: Disconnection1100
Failure code [DDTJKA] Lo clutch fill switch: Disconnection1102
Failure code [DDTKKA] 1st clutch fill switch: Disconnection1104
Failure code [DDTLKA] 2nd clutch fill switch: Disconnection1106
Failure code [DDTMKA] 3rd clutch fill switch: Disconnection1108
Failure code [DDTNKA] R clutch fill switch: Disconnection1110
Failure code [DDTPKA] 4th clutch fill switch: Disconnection1112
Failure code [DF10KA] Gear shift lever: Disconnection1114
Failure code [DF10KB] Gear shift lever: Short circuit1118
Failure code [DGE5KX] or VHMS_LED display: “n4” → “01”1122
Failure code [DGF1KX] Transmission oil temperature sensor: Out of input signal range1124
Failure code [DGR2KB] Trouble in retarder oil temperature sensor (rear wheel) system (Disconnection and short circuit)1126
Failure code [DGR2KZ] Trouble in retarder oil temperature sensor (rear wheel) system (Ground fault)1128
Failure code [DGR4KB] Trouble in retarder oil temperature sensor (front wheel) system (Disconnection and short circuit)1129
Failure code [DGR4KZ] Trouble in retarder oil temperature sensor (front wheel) system (Ground fault)1130
Failure code [DGR6KX] Steering oil temperature sensor: Input signal out of range1132
Failure code [DGT1KX] Torque converter oil temperature sensor: Out of input signal range1134
Troubleshooting by failure code, Part 71137
Failure code [DGT5KA] (or VHMS_LED display: “n3” → “12”) Left bank exhaust temperature sensor system (Front): Disconnection1139
Failure code [dGT5KA] (or VHMS_LED display: “n3” → “22”) Left bank exhaust temperature sensor system (Rear): Disconnection1142
Failure code [dGT5KB] (or VHMS_LED display: “n3” → “21”) Left bank exhaust temperature sensor system (Rear): Short circuit1148
Failure code [DGT6KA] (or VHMS_LED display: “n3” → “24”) Right bank exhaust temperature sensor system (Front): Disconnection1151
Failure code [dGT6KA] (or VHMS_LED display: “n3” → “26”) Right bank exhaust temperature sensor system (Rear): Disconnection1154
Failure code [DGT6KB] (or VHMS_LED display: “n3” → “23”) Right bank exhaust temperature sensor system (Front): Short circuit1157
Failure code [dGT6KB] (or VHMS_LED display: “n3” → “25”) Right bank exhaust temperature sensor system (Rear): Short circuit1160
Failure code [DHE5KB] (or VHMS_LED display: “n3” → “32”) (Blow-by pressure sensor: Short circuit)1164
Failure code [DHE5KY] (or VHMS_LED display: “n3” → “31”) (Blow-by pressure sensor: Short circuit with power supply line)1166
Failure code [DHP4KY] (or VHMS_LED display: “n5” → “44”) Suspension pressure sensor system: Short circuit (Right front)1168
Failure code [DHP4KZ] (or VHMS_LED display: “n5” → “43”) Suspension pressure sensor system: Disconnection or ground fault (Right front1170
Failure code [DHP5KY] (or VHMS_LED display: “n5” → “54”) Suspension pressure sensor system: Short circuit (Left front)1172
Failure code [DHP5KZ] (or VHMS_LED display: “n5” → “53”) Suspension pressure sensor system: Disconnection or ground fault (Left front)1174
Failure code [DHP6KA] Suspension pressure sensor system: Disconnection (Right rear)1176
Failure code [DHP6KX] Failure in suspension pressure sensor system trouble: Out of input signal range (Right rear)1178
Failure code [DHP6KY] (or VHMS_LED display: “n5” → “64”) Suspension pressure sensor system: Short circuit (Right rear)1180
Failure code [DHP6KZ] (or VHMS_LED display: “n5” → “63”) Suspension pressure sensor system: Disconnection or ground fault (Right rear)1182
Failure code [DHP7KA] Suspension pressure sensor system: Disconnection (Left rear)1184
Failure code [DHP7KX] Failure in suspension pressure sensor system: Out of input signal range (Left rear)1186
Failure code [DHP7KY] (or VHMS_LED display: “n5” → “74”) Suspension pressure sensor system: Short circuit (Left rear)1188
Failure code [DHP7KZ] (or VHMS_LED display: “n5” → “73”) Suspension pressure sensor system: Disconnection or ground fault (Left rear)1190
Failure code [DHT5KX] Torque converter oil pressure sensor: Out of input signal range1192
Failure code [DHT5L6] Torque converter oil pressure sensor: Disagreement of run and stop condition with signal1194
Failure code [DHU2KX] Front accumulator oil pressure sensor: Out of input signal range1196
Failure code [DHU3KX] Rear accumulator oil pressure sensor: Out of input signal range1198
Failure code [DHU6KX] Trouble in ABS control valve pressure sensor (Front right)1200
Failure code [DHU7KX] Trouble in ABS control valve pressure sensor (Front left)1202
Failure code [DHU8KX] Trouble in ABS control valve pressure sensor (Rear right)1204
Failure code [DHU9KX] Trouble in ABS control valve pressure sensor (Rear left)1206
Failure code [DJF1KA] Fuel level sensor: Disconnection1208
Failure code [DK30KX] Steering angle potentiometer: Trouble (Disconnection)1209
Failure code [DK51L5] Trouble in retarder lever potentiometer and RVS11210
Failure code [DK52KX] Failure in hoist lever potentiometer 1: Out of input signal range1214
Failure code [DK53L8] Failure in hoist lever potentiometer 2: Disagreement of analog signal1216
Failure code [DK54KX] Body positioner sensor: Out of input signal range1218
Failure code [DKD0L6] Failure in steering angle speed sensor1220
Failure code [DKH0KX] Pitch angle sensor: Out of input signal range1222
Failure code [DKH1KX] (or VHMS_LED display: “n4” → “33”) Pitch angle sensor: Abnormality1224
Failure code [DLF1KA] Transmission input shaft speed sensor: Disconnection1226
Failure code [DLF1LC] Transmission input shaft speed sensor: Disagreement of revolution speed signal1228
Failure code [DLF2KA] Transmission intermediate shaft speed sensor: Disconnection1230
Failure code [DLF2LC] Transmission intermediate shaft speed sensor: Disagreement of revolution speed signal1232
Troubleshooting by failure code, Part 81235
Failure code [DLF6KA] Disconnection in wheel speed sensor (Front right)1238
Failure code [DLF6L3] Trouble in wheel speed sensor (Front right)1240
Failure code [DLF7KA] Disconnection in wheel speed sensor (Front left)1242
Failure code [DLF7L3] Trouble in wheel speed sensor (Front left)1244
Failure code [DLF8KA] Wheel speed sensor: Disconnection (Rear right)1246
Failure code [DLF8L3] Wheel speed sensor: Disconnection (Rear right)1248
Failure code [DLF8LC] Wheel speed sensor: Trouble (Rear right)1250
Failure code [DLF8MA] Wheel speed sensor: Disconnection (Rear right)1250
Failure code [DLF9KA] Wheel speed sensor: Disconnection (Rear left)1252
Failure code [DLF9L3] Wheel speed sensor: Trouble (Rear left)1254
Failure code [DLF9LC] Wheel speed sensor: Trouble (Rear left)1256
Failure code [DLF9MA] Wheel speed sensor: Disconnection (Rear left)1256
Failure code [DLT3KA] Transmission output shaft speed sensor: Disconnection1258
Failure code [DLT3LC] Transmission output shaft speed sensor: Disagreement of revolution speed signal1260
Failure code [DLT4KA] Transmission output shaft speed sensor: Disconnection1262
Failure code [DLT4MA] Transmission output shaft speed sensor: Disconnection1264
Failure code [DUM7KY] Pre-lubrication operation lamp output abnormality: Hot short circuit1266
Failure code [DUM7KZ] Pre-lubrication operation lamp output abnormality: Disconnection or grounding fault1268
Failure code [DV00KB] Buzzer output: Short circuit1270
Failure code [DW2AKA] Main pressure variable valve output: Disconnection1272
Failure code [DW2AKB] Main pressure variable valve output circuit: Ground fault1274
Failure code [DW2AKY] Main pressure variable valve output circuit: Hot short1276
Failure code [DW2AL1] Main pressure variable valve: Defective reset1278
Failure code [DW2ALH] Main pressure variable valve: Malfunction1280
Failure code [DW2BKA] Main oil level selector valve output: Disconnection1281
Failure code [DW2BKB] Main oil level selector valve output circuit: Ground fault1282
Failure code [DW2BKY] Main oil level selector valve output circuit: Hot short1284
Failure code [DW2BL1] Main oil level selector valve: Defective reset1286
Failure code [DW2BLH] Main oil level selector valve: Malfunction1288
Failure code [DW2CKA] Transmission lubrication variable valve output: Disconnection1289
Failure code [DW2CKB] Transmission lubrication variable valve output circuit: Ground fault1290
Failure code [DW2CKY] Transmission lubrication variable valve output circuit: Hot short1292
Failure code [DW2CL1] Transmission lubrication variable valve: Defective reset1294
Failure code [DW2CLH] Transmission lubrication variable valve: Malfunction1296
Failure code [DW35KZ] Failure in output system of auto suspension solenoid 1: Disconnection or short circuit1298
Failure code [DW36KZ] Failure in output system of auto suspension solenoid 2: Disconnection or short circuit1300
Failure code [DW71KZ] Exhaust brake output system trouble (Disconection/Ground fault/Hot short)1302
Failure code [DW72KZ] Kick-out solenoid output system trouble: Disconnection or short circuit1304
Failure code [DW73KZ] Failure in hoist select valve output system: Disconnection or short circuit1306
Failure code [DW78KZ] Brake cooling valve (BCV) (rear wheel) output system trouble: Disconnection or short circuit1308
Failure code [DWNBK4] ASR shut-off valve: Trouble (Valve keeps operating)1310
Failure code [DWNBKA] ASR shut-off valve output circuit: Disconnection1312
Failure code [DWNBKB] ASR shut-off valve output circuit: Ground fault1314
Failure code [DWNBKY] ASR shut-off valve output circuit: Short circuit1316
Failure code [DWNBMA] ASR shut-off valve: Trouble (Valve does not operate)1316
Failure code [DWNDKZ] Trouble in ABS cut-off valve (Front) system1318
Failure code [DWNDMA] Defective ABS cut-off valve (Front)1320
Failure code [DWNEKZ] Trouble in ABS cut-off valve (Rear) system1322
Failure code [DWNEMA] Defective ABS cut-off valve (Rear)1324
Troubleshooting by failure code, Part 91327
Failure code [DX11K4] Rear brake proportional pressure reducing solenoid valve: Out of control1330
Failure code [DX11KA] Rear brake proportional pressure reducing solenoid valve output circuit: Disconnection1332
Failure code [DX11KB] Rear brake proportional pressure reducing solenoid valve: Short circuit1333
Failure code [DX11KY] Rear brake proportional pressure reducing solenoid valve: Short circuit to power source line1334
Failure code [DX11MA] Rear brake proportional pressure reducing solenoid valve: Malfunction1335
Failure code [DX12K4] Front brake proportional pressure reducing solenoid valve: Out of control1336
Failure code [DX12KA] Front brake proportional pressure reducing solenoid valve output circuit: Disconnection1338
Failure code [DX12KB] Front brake proportional pressure reducing solenoid valve: Short circuit1339
Failure code [DX12KY] Front brake proportional pressure reducing solenoid valve: Short circuit to power source line1340
Failure code [DX12MA] Front brake proportional pressure reducing solenoid valve: Malfunction1341
Failure code [DX13KA] Output circuit of hoist EPC valve: Disconnection1342
Failure code [DX13KB] Output circuit of hoist EPC valve: Short circuit1344
Failure code [DX13KY] Output circuit of hoist EPC valve: Short circuit with power source line1346
Failure code [DX17K4] ASR proportional pressure reducing solenoid valve (right): Trouble (Valve keeps operating)1348
Failure code [DX17KA] ASR proportional pressure reducing solenoid valve (right) output circuit: Disconnection1350
Failure code [DX17KB] ASR proportional pressure reducing solenoid valve (right) output circuit: Ground fault1352
Failure code [DX17KY] ASR proportional pressure reducing solenoid valve (right) output circuit: Short circuit1354
Failure code [DX17MA] ASR proportional pressure reducing solenoid valve (right): Trouble (Valve does not operate)1355
Failure code [DX18K4] ASR proportional pressure reducing solenoid valve (left): Trouble (Valve keeps operating)1356
Failure code [DX18KA] ASR proportional pressure reducing solenoid valve (left) output circuit: Disconnection1358
Failure code [DX18KB] ASR proportional pressure reducing solenoid valve (left) output circuit: Ground fault1360
Failure code [DX18KY] ASR proportional pressure reducing solenoid valve (left) output circuit: Short circuit1362
Failure code [DX18MA] ASR proportional pressure reducing solenoid valve (left): Trouble (Valve does not operate)1363
Failure code [DX21KA] Disconnection in ABS control valve output circuit (Front right)1364
Failure code [DX21KB] Ground fault in ABS control valve output circuit (Front right)1365
Failure code [DX21KY] Hot short in ABS control valve output circuit (Front right)1366
Failure code [DX21MA] Defective ABS control valve (Front right)1367
Failure code [DX22KA] Disconnection in ABS control valve output circuit (Front left)1368
Failure code [DX22KB] Ground fault in ABS control valve output circuit (Front left)1369
Failure code [DX22KY] Hot short in ABS control valve output circuit (Front left)1370
Failure code [DX22MA] Defective ABS control valve (Front left)1371
Failure code [DX23KA] Disconnection in ABS control valve output circuit (Rear right)1372
Failure code [DX23KB] Ground fault in ABS control valve output circuit (Rear right)1373
Failure code [DX23KY] Hot short in ABS control valve output circuit (Rear right)1374
Failure code [DX23MA] Defective ABS control valve (Rear right)1375
Failure code [DX24KA] Disconnection in ABS control valve output circuit (Rear left)1376
Failure code [DX24KB] Ground fault in ABS control valve output circuit (Rear left)1377
Failure code [DX24KY] Hot short in ABS control valve output circuit (Rear left)1378
Failure code [DX24MA] Defective ABS control valve (Rear left)1379
Failure code [DX25MA] Defective ABS front wheel system control valve1380
Failure code [DX26MA] Defective ABS rear wheel system control valve1380
Troubleshooting by failure code, Part 101383
Failure code [DXH1KA] Lockup clutch solenoid output circuit: Disconnection1385
Failure code [DXH1KB] Lock-up clutch solenoid output circuit: Short circuit1386
Failure code [DXH1KY] Lockup clutch solenoid output circuit: Short circuit to power source line1387
Failure code [DXH2KA] Hi clutch solenoid output circuit: Disconnection 1388
Failure code [DXH2KB] Hi clutch solenoid output circuit: Short circuit1390
Failure code [DXH2KY] Hi clutch solenoid output circuit: Short circuit to power source line1392
Failure code [DXH3KA] Lo clutch solenoid output circuit: Disconnection1396
Failure code [DXH3KB] Lo clutch solenoid output circuit: Short circuit1398
Failure code [DXH3KY] Lo clutch solenoid output circuit: Short circuit in power source line1400
Failure code [DXH4KA] 1st clutch solenoid output circuit: Disconnection1404
Failure code [DXH4KB] 1st clutch solenoid output circuit: Short circuit1406
Failure code [DXH4KY] 1st clutch solenoid output circuit: Short circuit to power source line1408
Failure code [DXH5KA] 2nd clutch solenoid output circuit: Disconnection1412
Failure code [DXH5KB] 2nd clutch solenoid output circuit: Short circuit1414
Failure code [DXH5KY] 2nd clutch solenoid output circuit: Short circuit in power source line1416
Failure code [DXH6KA] 3rd clutch solenoid output circuit: Disconnection1420
Failure code [DXH6KB] 3rd clutch solenoid output circuit: Short circuit1422
Failure code [DXH6KY] 3rd clutch solenoid output circuit: Short circuit to power source line1424
Failure code [DXH7KA] R clutch solenoid output circuit: Disconnection1428
Failure code [DXH7KB] R clutch solenoid output circuit: Short circuit1430
Failure code [DXH7KY] R clutch solenoid output circuit: Short circuit to power source line1432
Failure code [DXHHKA] 4th clutch solenoid output circuit: Disconnection1434
Failure code [DXHHKB] 4th clutch solenoid output circuit: Short circuit1436
Failure code [DXHHKY] 4th clutch solenoid output circuit: Short circuit to power source line1438
Failure code [F@BBZL] (or VHMS_LED display: “n3” → “38”) (Blow-by pressure: High error)1442
Failure code [F@BYNS] (or VHMS_LED display “n3” → “61”) Left front exhaust temperature sensor (1): Exhaust temperature abnormal rise1444
Failure code [f@BYNS] (or VHMS_LED display “n3” → “71”) Left rear exhaust temperature sensor (1): Exhaust temperature abnormal rise1446
Failure code [F@BZNS] (or VHMS_LED display “n3” → “81”) Right front exhaust temperature sensor (1): Exhaust temperature abnormal rise1448
Failure code [f@BZNS] (or VHMS_LED display “n3” → “91”) Right rear exhaust temperature sensor (1): Exhaust temperature abnormal rise1450
Failure code [F@BYNR] (or VHMS_LED display “n3” → “62”) Left front exhaust temperature sensor (2): Exhaust temperature abnormal rise1452
Failure code [f@BYNR] (or VHMS_LED display “n3” → “72”) Left rear exhaust temperature sensor (2): Exhaust temperature abnormal rise1454
Failure code [F@BZNR] (or VHMS_LED display “n3” → “82”) Right front exhaust temperature sensor (2): Exhaust temperature abnormal rise1456
Failure code [f@BZNR] (or VHMS_LED display “n3” → “92”) Right rear exhaust temperature sensor (2): Exhaust temperature abnormal rise1458
Troubleshooting of electrical system(E-mode)1461
Before troubleshooting of electric system1463
Contents of troubleshooting table1464
E-1 Engine does not start1465
E-2 Automatic preheating does not operate1468
E-3 Machine monitor does not display all, when starting switch is turned ON1472
E-4 Machine monitor does not operate when starting switch is OFF1474
E-5 Alarm buzzer does not sound1476
E-6 Alarm buzzer does not stop sounding1478
E-7 Gauges of machine monitor, caution lamps or character display section do not display properly1479
E-8 A selection of the display in character display section cannot be changed1481
E-9 Power mode selecting function does not operate properly1484
E-10 AISS function does not operate properly1485
E-11 Seat belt caution lamp does not display properly1486
E-12 Turn signal lamp or turning lamp (hazard lamp) do not work properly1487
E-13 Night illumination (lighting) does not work properly1490
E-14 Emergency steering does not operate1502
E-15 Hoist lever does not operate normally1507
E-16 Power supply system (Air conditioner does not operate)1510
E-17 Compressor and refrigerant system (Air is not cooled)1512
E-18 Blower motor system (Air does not come out or air flow is abnormal)1514
E-19 Electric heater by external power does not operate1516
Troubleshooting of hydraulic and mechanical system (H-mode)1521
Contents of troubleshooting table1523
H-1 Machine does not start1524
H-2 Machine does not travel smoothly (hunting)1526
H-3 Lockup cannot be cancelled1526
H-4 Excessive shock when starting or shifting excessive1527
H-5 Transmission does not shift up1528
H-6 Machine lacks power or speed when traveling1530
H-7 Time lag is excessive when starting or shifting gear1534
H-8 Torque converter oil temperature is high1536
H-9 Torque converter oil pressure is low1537
H-10 Front brake is ineffective1538
H-11 Rear brake is ineffective1539
H-12 Steering wheel is heavy1540
H-13 Steering wheel does not work1541
H-14 Steering wheel vibrates1542
H-15 Dump body lifting speed is slow1543
H-16 Dump body does not work1544
H-17 Excessive hydraulic drift of dump body1545
Troubleshooting of engine (S-mode)1547
Method of using troubleshooting charts1549
S-1 Starting performance is poor1552
S-2 Engine does not start1553
S-3 Engine does not pick up smoothly1556
S-4 Engine stops during operations1557
S-5 Engine does not rotate smoothly1558
S-6 Engine lacks output (or lacks power)1559
S-7 Exhaust smoke is black (incomplete combustion)1561
S-8 Oil consumption is excessive (or exhaust smoke is blue)1562
S-9 Oil becomes contaminated quickly1563
S-10 Fuel consumption is excessive1564
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1565
S-12 Oil pressure drops1566
S-13 Oil level rises (Entry of coolant or fuel)1567
S-14 Coolant temperature becomes too high (overheating)1568
S-15 Abnormal noise is made1569
S-16 Vibration is excessive1570
50 Disassembly and assembly 1573
General information on disassembly and assembly1573
Precautions before work1574
How to read this manual1575
Coating materials list1577
Special tool list1580
Sketches of special tools1587
Engine and cooling system1623
Removal and installation of fuel supply pump assembly1624
Removal and installation of fuel injector assembly1626
Removal and installation of cylinder head assembly1627
Removal and installation of engine hood assembly1640
Removal and installation of radiator assembly1641
Removal and installation of engine assembly1650
Removal and installation of engine front oil seal1655
Removal and installation of engine rear oil seal1658
Power train, Part 11663
Removal and installation of front drive shaft1664
Removal and installation of rear drive shaft assembly1666
Removal and installation of output shaft assembly1667
Disassembly and assembly of damper assembly1673
Removal and installation of torque converter and transmission assemblies1675
Disconnection and connection of torque converter assembly and transmission assembly1678
Disassembly and assembly of torque converter and PTO assembly1689
Disassembly and assembly of transmission assembly1707
Power train, Part 21747
Removal and installation of final drive carrier assembly1748
Disassembly and assembly of final drive carrier assembly1750
Removal and installation of differential assembly1752
Disassembly and assembly of differential assembly1755
Steering system1775
Removal and installation of steering cylinder assembly1776
Disassembly and assembly of steering cylinder assembly1777
Removal and installation of steering valve assembly1781
Disassembly and assembly of steering valve assembly1782
Brake system1795
Removal and installation of front wheel hub and brake assembly1796
Disassembly and assembly of front wheel hub and brake assembly1800
Removal and installation of final drive and rear brake assembly1808
Disassembly and assembly of final drive and rear brake assembly1810
Undercarriage and frame1851
Removal and installation of front wheel assembly1852
Removal and installation of rear wheel assembly1854
Removal and installation of front suspension cylinder assembly1856
Disassembly and assembly of front suspension cylinder assembly (cylinder with buffer ring)1858
Removal and installation of king pin1863
Removal and installation of rear suspension cylinder assembly1865
Disassembly and assembly of rear suspension cylinder assembly1866
Hydraulic system1875
Removal and installation of hoist valve assembly1876
Disassembly and assembly of hoist valve assembly1877
Disassembly and assembly of hoist cylinder assembly1879
Body1883
Removal and installation of body assembly1884
Cab and its attachments1889
Disassembly and assembly of operator’s seat assembly1890
Removal and installation of air conditioner unit assembly1900
Electrical system1903
Removal and installation of engine controller assembly1904
Removal and installation of transmission controller assembly11904
Removal and installation of retarder controller assembly1905
Removal and installation of ABS controller assembly1905
Removal and installation of VHMS controller assembly1906
90 Diagrams and drawings1909
Hydraulic diagrams and drawings1909
Power train hydraulic circuit diagram1911
Steering and hoist hydraulic circuit diagram1913
Brake hydraulic circuit diagram1917
Brake hydraulic circuit diagram (ASR specification)1919
Electrical diagrams and drawings1923
Electrical circuit diagram for outside cab (1/3)1925
Electrical circuit diagram for outside cab (2/3)1927
Electrical circuit diagram for outside cab (3/3)1929
Electrical circuit diagram for inside cab (1/3)1931
Electrical circuit diagram for inside cab (2/3)1933
Electrical circuit diagram for inside cab (3/3)1935
Electrical circuit diagram for VHMS1937
Electrical circuit diagram for ASR1939
Air conditioner electrical circuit diagram1941
Electrical circuit diagram for auto greasing1943
Electrical circuit diagram of external power supply heater1945
Connectors table and arrangement drawing 1947

S.M 30/12/24