Komatsu HD785-7 Install guide
CEBM019012
Shop
Manual
DUMP TRUCK
SERIAL NUMBERS A10001 &UP
®
HD785-7 1
SEN01276-12
DUMP TRUCK
1SHOP MANUAL
HD785-7
Machine model Serial number
HD785-7 A10001 and up
00 Index and foreword 1
Index
Composition of shop manual .......................................................................................................................... 2
Table of contents............................................................................................................................................. 4
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SEN01276-12 00 Index and foreword
2HD785-7
Composition of shop manual 1
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q
QQ
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN01274-12
00 Index and foreword SEN01275-12
Index SEN01276-12 q
Foreword and general information SEN01277-04
01 Specification SEN01278-03
Specification and technical data SEN01279-03
10 Structure, function and maintenance standard SEN01280-07
Engine and cooling system SEN01281-01
Power train, Part 1 SEN01282-03
Power train, Part 2 SEN01283-01
Steering system SEN01284-01
Brake system SEN01285-04 q
Undercarriage and frame SEN01286-02
Hydraulic system SEN01287-03
Work equipment (Body) SEN04681-00
Cab and its attachments SEN01288-01
Electrical system, Part 1 SEN01289-01
Electrical system, Part 2 SEN01290-05 q
Electrical system, Part 3 SEN01291-03
Electrical system, Part 4 SEN01292-02
20 Standard value table SEN01293-01
Standard service value table SEN01769-01
30 Testing and adjusting SEN01294-04
Testing and adjusting, Part 1 SEN01770-02 q
Testing and adjusting, Part 2 SEN01771-04 q
Testing and adjusting, Part 3 SEN01772-03
Testing and adjusting, Part 4 SEN01773-02
Testing and adjusting, Part 5 SEN01774-03
40 Troubleshooting SEN01295-03
Failure code table and fuse locations SEN01936-02
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00 Index and foreword SEN01276-12
HD785-7 3
General information on troubleshooting SEN01937-03
Troubleshooting by failure code, Part 1 SEN01938-01
Troubleshooting by failure code, Part 2 SEN01939-02
Troubleshooting by failure code, Part 3 SEN01940-02
Troubleshooting by failure code, Part 4 SEN01941-02
Troubleshooting by failure code, Part 5 SEN01942-02
Troubleshooting by failure code, Part 6 SEN01943-02
Troubleshooting by failure code, Part 7 SEN01944-01
Troubleshooting by failure code, Part 8 SEN01945-02
Troubleshooting by failure code, Part 9 SEN01946-02
Troubleshooting by failure code, Part 10 SEN01947-01
Troubleshooting of electrical system (E-mode) SEN01948-03
Troubleshooting of hydraulic and mechanical system (H-mode) SEN01949-01
Troubleshooting of engine (S-mode) SEN01950-01
50 Disassembly and assembly SEN01296-04
General information on disassembly and assembly SEN01951-03
Engine and cooling system SEN01952-02
Power train, Part 1 SEN01953-02
Power train, Part 2 SEN02106-03
Steering system SEN04641-00
Brake system SEN04642-01
Undercarriage and frame SEN04643-01
Hydraulic system SEN04644-00
Body SEN04645-00
Cab and its attachments SEN04646-00
Electrical system SEN04647-01
90 Diagrams and drawings SEN01297-06
Hydraulic diagrams and drawings SEN01298-03
Electrical diagrams and drawings SEN01299-06
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SEN01276-12 00 Index and foreword
4HD785-7
Table of contents 1
00 Index and foreword
Index SEN01276-12
Composition of shop manual....................................................................................................... 2
Table of contents ......................................................................................................................... 4
Foreword and general information SEN01277-04
Safety notice................................................................................................................................ 2
How to read the shop manual .....................................................................................................7
Explanation of terms for maintenance standard.......................................................................... 9
Handling of electric equipment and hydraulic component........................................................... 11
Handling of connectors newly used for engines.......................................................................... 20
How to read electric wire code .................................................................................................... 23
Precautions when carrying out operation .................................................................................... 26
Method of disassembling and connecting push-pull type coupler ............................................... 29
Standard tightening torque table ................................................................................................. 32
Conversion table ......................................................................................................................... 36
01 Specification
Specification and technical data SEN01279-03
Specification drawing................................................................................................................... 2
Specifications .............................................................................................................................. 4
Weight table ................................................................................................................................ 7
Fuel, coolant and lubricants ........................................................................................................ 8
10 Structure, function and maintenance standard
Engine and cooling system SEN01281-01
Radiator, brake, torque converter oil cooler, aftercooler, steering, hoist oil cooler ...................... 2
Fuel system ................................................................................................................................. 4
Power train, Part 1 SEN01282-03
Power train skeleton.................................................................................................................... 2
Output shaft................................................................................................................................. 4
Drive shaft ................................................................................................................................... 6
Torque converter and transmission hydraulic piping ................................................................... 8
Brake cooling oil control valve (BCV) .......................................................................................... 10
Torque converter ......................................................................................................................... 11
Torque converter valve ................................................................................................................ 19
Transmission ............................................................................................................................... 22
Transmission control valve .......................................................................................................... 50
ECMV .......................................................................................................................................... 52
Lubricating oil amount selector valve .......................................................................................... 59
Power train, Part 2 SEN01283-01
Axle ............................................................................................................................................. 2
Differential ................................................................................................................................... 4
Final drive.................................................................................................................................... 5
Wheels ........................................................................................................................................ 6
Steering system SEN01284-01
Steering column........................................................................................................................... 2
Steering linkage........................................................................................................................... 3
Brake system SEN01285-04
Brake piping ................................................................................................................................ 2
Brake valve.................................................................................................................................. 4
Secondary brake valve................................................................................................................ 7
Accumulator charge valve ........................................................................................................... 8
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00 Index and foreword SEN01276-12
HD785-7 5
Accumulator ................................................................................................................................ 12
Slack adjuster.............................................................................................................................. 14
Brake, parking brake ................................................................................................................... 18
Parking brake solenoid................................................................................................................ 24
Retarder control valve ................................................................................................................. 25
Exhaust brake ............................................................................................................................. 26
Undercarriage and frame SEN01286-02
Suspension ................................................................................................................................. 2
Suspension cylinder .................................................................................................................... 4
Rear axle support........................................................................................................................ 12
Hydraulic system SEN01287-03
Steering and hoist hydraulic piping .............................................................................................2
Steering, hoist filter (high pressure circuit) ..................................................................................4
Dump body control ...................................................................................................................... 6
Hydraulic tank ............................................................................................................................. 8
Steering valve.............................................................................................................................. 9
Crossover relief valve.................................................................................................................. 13
Steering cylinder.......................................................................................................................... 14
Steering control valve.................................................................................................................. 15
Hoist valve................................................................................................................................... 24
Dump control valve (EPC valve) ................................................................................................. 30
Hydraulic pump ........................................................................................................................... 34
Work equipment (Body) SEN04681-00
Auto greasing system.................................................................................................................. 2
Hoist cylinder............................................................................................................................... 13
Cab and its attachments SEN01288-01
ROPS cab ................................................................................................................................... 2
Air conditioner ............................................................................................................................. 3
Rear view monitor ....................................................................................................................... 12
Controller related......................................................................................................................... 15
Electrical system, Part 1 SEN01289-01
Machine monitor system ............................................................................................................. 2
Electrical system, Part 2 SEN01290-05
Automatic shift control system .................................................................................................... 2
Automatic emergency steering system ....................................................................................... 22
Automatic suspension system.....................................................................................................26
Retarder control system .............................................................................................................. 29
Battery disconnector switch ........................................................................................................ 42
Dump control lever ...................................................................................................................... 46
Electrical system, Part 3 SEN01291-03
VHMS controller related .............................................................................................................. 2
ABS/ASR system ........................................................................................................................ 28
Altitude setting function ............................................................................................................... 46
Electrical system, Part 4 SEN01292-02
Sensors, switches ....................................................................................................................... 2
20 Standard value table
Standard service value table SEN01769-01
Standard value table for engine .................................................................................................. 2
Standard value table for machine................................................................................................4
30 Testing and adjusting
Testing and adjusting, Part 1 SEN01770-02
Testing and adjusting tools list .................................................................................................... 3
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SEN01276-12 00 Index and foreword
6HD785-7
Sketch of special tool .................................................................................................................. 8
Testing engine speed .................................................................................................................. 9
Testing air supply pressure (boost pressure) .............................................................................. 10
Testing exhaust temperature ....................................................................................................... 12
Testing exhaust gas color............................................................................................................ 14
Adjustment of valve clearance .................................................................................................... 16
Testing compression pressure..................................................................................................... 18
Testing blow-by pressure............................................................................................................. 20
Testing engine oil pressure.......................................................................................................... 21
Handling of fuel system devices.................................................................................................. 22
Releasing residual pressure from fuel system ............................................................................ 22
Testing fuel pressure ................................................................................................................... 23
Reduced cylinder mode operation............................................................................................... 24
No-injection cranking................................................................................................................... 24
Testing leakage-from pressure limiter and return rate from injector ............................................ 25
Bleeding air from fuel circuit (Standard spec.)............................................................................. 28
Bleeding air from fuel circuit (Extra low-grade fuel spec.) ........................................................... 30
Testing the fuel circuit for leakage ............................................................................................... 32
Replacement and adjustment of fan belt..................................................................................... 33
Testing and adjusting alternator belt tension ............................................................................... 34
Testing and adjusting air conditioner compressor belt ................................................................ 35
Testing and adjusting, Part 2 SEN01771-04
Testing torque converter stall speed............................................................................................3
Testing power train oil pressure................................................................................................... 5
Adjusting transmission speed sensor.......................................................................................... 13
Testing and adjusting brake oil pressure ..................................................................................... 14
Testing of accumulator nitrogen gas pressure and procedure for
charging accumulator with nitrogen gas .................................................................................. 17
Testing brake performance.......................................................................................................... 22
Bleeding air from brake circuit..................................................................................................... 24
Bleeding air from ASR circuit (if equipped) ................................................................................. 26
Testing wear of front brake disc................................................................................................... 27
Testing wear of rear brake disc ................................................................................................... 28
Method of releasing parking brake in an emergency .................................................................. 29
Testing and adjusting front suspension cylinder.......................................................................... 30
Testing and adjusting rear suspension cylinder........................................................................... 34
Testing and adjusting front suspension cylinder (Automatic suspension specification) .............. 38
Testing and adjusting hydraulic pressure in steering, hoist circuit............................................... 39
Testing and adjusting oil pressure in dump EPC circuit .............................................................. 42
Air bleeding from steering cylinder .............................................................................................. 43
Procedure for raising dump body in emergency.......................................................................... 44
Adjusting body positioner sensor ................................................................................................45
Handling of high voltage circuit of engine controller.................................................................... 47
Adjusting transmission controller................................................................................................. 47
Method for emergency escape at electrical system failure ......................................................... 48
Testing and adjusting, Part 3 SEN01772-03
Setting and adjusting of devices.................................................................................................. 2
Testing and adjusting, Part 4 SEN01773-02
Special functions of machine monitor (EMMS)............................................................................ 2
Testing and adjusting, Part 5 SEN01774-03
Opening ORBCOMM terminal..................................................................................................... 2
VHMS controller initial setting procedure .................................................................................... 4
Precautions for replacing VHMS controller ................................................................................. 29
Pm Clinic check sheet ................................................................................................................. 35
Initial setting of payload meter..................................................................................................... 39
Setting of payload meter built in VHMS....................................................................................... 40
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00 Index and foreword SEN01276-12
HD785-7 7
40 Troubleshooting
Failure code table and fuse locations SEN01936-02
Failure codes table...................................................................................................................... 2
Fuse locations ............................................................................................................................. 18
General information on troubleshooting SEN01937-03
Points to remember when troubleshooting.................................................................................. 2
Sequence of events in troubleshooting ....................................................................................... 3
Check before troubleshooting ..................................................................................................... 4
Classification and procedures for troubleshooting ...................................................................... 5
Contents of troubleshooting table................................................................................................ 6
Connection table for connector pin numbers .............................................................................. 8
T-branch box and T-branch adapter table ................................................................................... 44
Troubleshooting by failure code, Part 1 SEN01938-01
Failure code [1500L0] Dual engagement .................................................................................... 3
Failure code [15B0NX] Transmission oil filter: Clogging ............................................................. 4
Failure code [15F0KM] R oF shifting abuse 1: Mistake in operation ........................................ 6
Failure code [15F0MB] R oF shifting abuse 2: Mistake in operation ........................................ 6
Failure code [15F7KM] Forward clutch disk abuse: Mistake in operation or setting ................... 7
Failure code [15G0MW] R clutch: Slipping ................................................................................. 8
Failure code [15G7KM] Reverse clutch disk abuse: Mistake in operation or setting .................. 10
Failure code [15H0MW] Hi clutch: Slipping................................................................................. 12
Failure code [15J0MW] Lo clutch: Slipping ................................................................................. 14
Failure code [15K0MW] 1st clutch: Slipping................................................................................ 16
Failure code [15L0MW] 2nd clutch: Slipping............................................................................... 18
Failure code [15M0MW] 3rd clutch: Slipping............................................................................... 20
Failure code [15N0MW] 4th clutch: Slipping ............................................................................... 22
Failure code [15SBL1] R clutch solenoid: Fill signal is ON when command current is OFF....... 24
Failure code [15SBMA] R clutch solenoid: Malfunction .............................................................. 26
Failure code [15SCL1] Hi clutch solenoid: Fill signal is ON when command current is OFF...... 28
Failure code [15SCMA] Hi clutch solenoid: Malfunction ............................................................. 32
Failure code [15SDL1] Lo clutch solenoid: Fill signal is ON when command current is OFF ..... 34
Failure code [15SDMA] Lo clutch solenoid: Malfunction............................................................. 38
Failure code [15SEL1] 1st clutch solenoid: Fill signal is ON when command current is OFF..... 40
Failure code [15SEMA] 1st clutch solenoid: Malfunction ............................................................ 44
Troubleshooting by failure code, Part 2 SEN01939-02
Failure code [15SFL1] 2nd clutch solenoid: Fill signal is ON when command current is OFF.... 3
Failure code [15SFMA] 2nd clutch solenoid: Malfunction ........................................................... 6
Failure code [15SGL1] 3rd clutch solenoid: Fill signal is ON when command current is OFF.... 8
Failure code [15SGMA] 3rd clutch solenoid: Malfunction ........................................................... 12
Failure code [15SHL1] 4th clutch solenoid: Fill signal is ON when command current is OFF .... 14
Failure code [15SHMA] 4th clutch solenoid: Malfunction............................................................ 18
Failure code [15SJMA] Lockup clutch solenoid: Malfunction ...................................................... 20
Failure code [2F00KM] Parking brake: Mistake in operation or setting....................................... 21
Failure code [2G42ZG] Accumulator: Oil pressure reduction (Front).......................................... 24
Failure code [2G43ZG] Accumulator: Oil pressure reduction (Rear) .......................................... 24
Failure code [989A00] Engine over run prevention command signal: Operating........................ 25
Failure code [989D00] Rear section tipping over alarm: Alarm is activated................................ 25
Failure code [A570NX] Engine oil filter: Clogging ....................................................................... 26
Failure code [AA10NX] Air cleaner element: Clogging ............................................................... 28
Failure code [AB00L4] Alternator: Failure on battery charge circuit
(R terminal signal is present and engine is stopped)............................................................... 30
Failure code [AB00MA] Alternator: Malfunction .......................................................................... 32
Failure code [AB00MB] Alternator: Failure on battery charge circuit
(Absence of R terminal signal and detection error) ................................................................. 34
Failure code [B@BAZG] Abnormal lowering of engine oil pressure: Lowering of oil pressure ... 36
Failure code [B@BAZK] Engine oil: Level too low ...................................................................... 38
Failure code [B@BCNS] Engine: Overheat ................................................................................ 40
Failure code [B@BCZK] Lowering of radiator coolant: Lowering of level ................................... 42
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SEN01276-12 00 Index and foreword
8HD785-7
Failure code [B@BFZK] Lowering of fuel level............................................................................ 44
Failure code [B@C6NS] Brake cooling oil: Overheating (Front) ................................................. 46
Failure code [B@C7NS] Brake cooling oil: Overheating (Rear).................................................. 47
Failure code [B@CENS] Overheating of torque converter oil ..................................................... 48
Failure code [B@GAZK] Battery electrolyte level: Lowering of level........................................... 49
Failure code [B@JANS] Steering oil: Overheat........................................................................... 50
Troubleshooting by failure code, Part 3 SEN01940-02
Failure code [CA111] Engine controller (Left bank): Internal abnormality ................................... 4
Failure code [CB111] Engine controller (Right bank): Internal abnormality ................................. 6
Failure code [CA115] Abnormal engine Ne and Bkup speed sensors (Left bank):
Abnormal speed sensor signal ................................................................................................ 8
Failure code [CB115] Abnormal engine Ne and Bkup speed sensors (Right bank):
Abnormal speed sensor signal ................................................................................................ 9
Failure code [CA122] Charge pressure sensor too high (At left bank only):
Excessively high voltage detected........................................................................................... 10
Failure code [CA123] Charge pressure sensor too low (At left bank only):
Excessively low voltage detected ............................................................................................ 12
Failure code [CA131] Throttle sensor high error (At left bank only) ............................................ 14
Failure code [CA132] Throttle sensor low error (At left bank only).............................................. 17
Failure code [CA135] Oil pressure sensor too high (At left bank only):
Excessively high voltage detected........................................................................................... 18
Failure code [CA141] Oil pressure sensor too low (At left bank only):
Excessively low voltage detected ............................................................................................ 20
Failure code [CA144] Coolant temperature sensor too high:
Excessively high voltage detected........................................................................................... 22
Failure code [CA145] Coolant temperature sensor too low (At left bank only):
Excessively low voltage detected ............................................................................................ 24
Failure code [CA153] Charge temperature sensor too high (At left bank only):
Excessively high voltage detected........................................................................................... 26
Failure code [CA154] Charge temperature sensor too low (At left bank only):
Excessively low voltage detected ............................................................................................ 28
Failure code [CA187] Sensor power supply (2) abnormally low level (Left bank):
Low voltage detection .............................................................................................................. 30
Failure code [CB187] Sensor power supply (2) abnormally low level (Right bank):
Low voltage detection .............................................................................................................. 30
Failure code [CA212] Engine oil temperature sensor abnormally high level (At left bank only):
High voltage detection ............................................................................................................. 32
Failure code [CA213] Engine oil temperature sensor abnormally low level (At left bank only):
Low voltage detection .............................................................................................................. 34
Failure code [CA221] Atmospheric pressure sensor too high (At left bank only):
Excessively high voltage detected........................................................................................... 36
Failure code [CA222] Atmospheric pressure sensor too low (At left bank only):
Excessively low voltage detected ............................................................................................ 38
Failure code [CA227] Sensor power source (2) too high (Left bank):
Excessively high voltage detected........................................................................................... 40
Failure code [CB227] Sensor power supply (2) abnormally high level (Right bank):
High voltage detection ............................................................................................................. 42
Failure code [CA234] Engine over speed (At left bank only): Excessively high speed ............... 44
Failure code [CA238] Abnormal power source for Ne speed sensor (At left bank only):
Excessively low voltage detected ............................................................................................ 46
Failure code [CB238] Abnormal power source for Ne speed sensor (At right bank only):
Excessively low voltage detected ............................................................................................ 48
Failure code [CA263] Fuel temperature sensor too high (Left bank):
Excessively high voltage detected........................................................................................... 50
Failure code [CB263] Fuel temperature sensor too high (Right bank):
Excessively high voltage detected........................................................................................... 52
Failure code [CA265] Fuel temperature sensor abnormally low level (Left bank):
Low voltage detection .............................................................................................................. 54
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00 Index and foreword SEN01276-12
HD785-7 9
Failure code [CB265] Fuel temperature sensor abnormally low level (Right bank):
Low voltage detection .............................................................................................................. 54
Failure code [CA271] PCV1 short circuit (Left bank): Short circuit ............................................. 55
Failure code [CB271] PCV1 short circuit (Right bank): Short circuit ........................................... 56
Failure code [CA272] PCV1 disconnection (Left bank): Disconnection ...................................... 57
Failure code [CB272] PCV1 disconnection (Right bank): Disconnection.................................... 58
Failure code [CA273] PCV2 short circuit (Left bank): Short circuit ............................................. 59
Failure code [CB273] PCV2 short circuit (Right bank): Short circuit ........................................... 60
Failure code [CA274] PCV2 disconnection (Left bank): Disconnection ...................................... 61
Failure code [CB274] PCV2 disconnection (Right bank): Disconnection.................................... 62
Troubleshooting by failure code, Part 4 SEN01941-02
Failure code [CA322] Injector No. 1 (L/B No.1) system disconnection or short circuit (Left bank):
Disconnection, short circuit...................................................................................................... 4
Failure code [CA323] Injector No. 5 (L/B No.5) system disconnection or short circuit (Left bank):
Disconnection, short circuit...................................................................................................... 6
Failure code [CA324] Injector No. 3 (L/B No.3) system disconnection or short circuit (Left bank):
Disconnection, short circuit...................................................................................................... 8
Failure code [CA325] Injector No. 6 (L/B No.6) system disconnection or short circuit (Left bank):
Disconnection, short circuit...................................................................................................... 10
Failure code [CA331] Injector No. 2 (L/B No.2) system disconnection or short circuit (Left bank):
Disconnection, short circuit...................................................................................................... 12
Failure code [CA332] Injector No. 4 (L/B No.4) system disconnection or short circuit (Left bank):
Disconnection, short circuit...................................................................................................... 14
Failure code [CA342] Engine controller data mismatch (Left bank): Mismatch........................... 16
Failure code [CB342] Engine controller data mismatch (Right bank): Mismatch ........................ 16
Failure code [CA351] Abnormal injector drive circuit (Left bank): Abnormal circuit .................... 18
Failure code [CB351] Injector drive circuit abnormality (Right bank): Circuit abnormality .......... 20
Failure code [CA352] Sensor power supply (1) abnormally low level (Left bank):
Low voltage detection .............................................................................................................. 22
Failure code [CB352] Sensor power supply (1) abnormally low level (Right bank):
Low voltage detection .............................................................................................................. 22
Failure code [CA386] Sensor power supply (1) abnormally high level (Left bank):
High voltage detection ............................................................................................................. 24
Failure code [CB386] Sensor power supply (1) abnormally high level (Right bank):
High voltage detection ............................................................................................................. 26
Failure code [CA431] Trouble in idle validation switch................................................................ 28
Failure code [CA432] Idle validation action error ........................................................................ 32
Failure code [CA441] Power supply voltage abnormally low level (Left bank):
Low voltage detection .............................................................................................................. 33
Failure code [CB441] Power supply voltage abnormally low level (Right bank):
Low voltage detection .............................................................................................................. 33
Failure code [CA442] Power supply voltage abnormally high level (Left bank):
High voltage detection ............................................................................................................. 34
Failure code [CB442] Power supply voltage abnormally high level (Right bank):
High voltage detection ............................................................................................................. 34
Failure code [CA449] Common rail abnormally high pressure (2) (Left bank):
Abnormally high pressure occurrence ..................................................................................... 35
Failure code [CB449] Common rail abnormally high pressure (2) (Right bank):
Abnormally high pressure occurrence ..................................................................................... 35
Failure code [CA451] Common rail pressure sensor too high (Left bank):
Excessively high voltage detected........................................................................................... 36
Failure code [CB451] Common rail pressure sensor abnormally high level (Right bank):
High voltage detection ............................................................................................................. 38
Failure code [CA452] Common rail pressure sensor abnormally low level (Left bank):
Abnormally low voltage detection ............................................................................................ 40
Failure code [CB452] Common rail pressure sensor abnormally low level (Right bank):
Abnormally low voltage detection ............................................................................................ 40
SEN01276-12 00 Index and foreword
10 HD785-7
Failure code [CA553] Common rail pressure too high (1) (Left bank):
Excessively high pressure detected ........................................................................................ 41
Failure code [CB553] Common rail pressure too high (1) (Right bank):
Excessively high pressure detected ........................................................................................ 42
Failure code [CA554] In-range error in common rail pressure sensor (Left bank):
In-range error........................................................................................................................... 43
Failure code [CB554] In-range error in common rail pressure sensor (Right bank):
In-range error........................................................................................................................... 43
Failure code [CA559] Loss of pressure feed from supply pump (1) (Left bank):
Loss of pressure feed detected ............................................................................................... 44
Failure code [CB559] Loss of pressure feed from supply pump (1) (Right bank):
Loss of pressure feed detected ............................................................................................... 48
Failure code [CA689] Abnormal engine Ne speed sensor (Left bank): Abnormal signal ............ 52
Failure code [CB689] Abnormal engine Ne speed sensor (Right bank): Abnormal signal.......... 54
Failure code [CA691] Intake air temperature sensor abnormally high level (At left bank only):
High voltage detection ............................................................................................................. 56
Failure code [CA692] Intake air temperature sensor abnormally low level (At left bank only):
Low voltage detection .............................................................................................................. 58
Failure code [CA731] Abnormal engine Bkup speed sensor phase (Left bank):
Abnormal phase....................................................................................................................... 59
Failure code [CB731] Abnormal engine Bkup speed sensor phase (Right bank):
Abnormal phase....................................................................................................................... 59
Troubleshooting by failure code, Part 5 SEN01942-02
Failure code [CA757] Loss of all engine controller data (Left bank): Loss of all data.................. 3
Failure code [CB757] Loss of all engine controller data (Right bank): Loss of all data ............... 3
Failure code [CA778] Abnormal engine Bkup speed sensor (Left bank):
Abnormal Bkup signal.............................................................................................................. 4
Failure code [CB778] Engine Bkup speed sensor abnormality (Right bank):
Bkup signal error...................................................................................................................... 6
Failure code [CA781] Inter-multicontroller communication error (Left bank):
Communication error ............................................................................................................... 8
Failure code [CB781] Inter-multicontroller communication error (Right bank):
Communication error ............................................................................................................... 10
Failure code [CA1257] Multicontroller distinction wiring harness key error (Left bank):
Distinction error........................................................................................................................ 11
Failure code [CB1257] Multicontroller distinction wiring harness key error (Right bank):
Distinction error........................................................................................................................ 12
Failure code [CB1548] Injector #7 (R/B #1) system disconnection/short circuit (Right bank):
Disconnection/Short circuit ...................................................................................................... 14
Failure code [CB1549] Injector #8 (R/B #2) system disconnection/short circuit (Right bank):
Disconnection/Short circuit ...................................................................................................... 16
Failure code [CB1551] Injector #10 (R/B #4) system disconnection/short circuit (Right bank):
Disconnection/Short circuit ...................................................................................................... 18
Failure code [CB1552] Injector #11 (R/B #5) system disconnection/short circuit (Right bank):
Disconnection/Short circuit ...................................................................................................... 20
Failure code [CB1553] Injector #12 (R/B #6) system disconnection/short circuit (Right bank):
Disconnection/Short circuit ...................................................................................................... 22
Failure code [CB1622] Injector #9 (R/B #3) system disconnection/short circuit (Right bank):
Disconnection/Short circuit ...................................................................................................... 24
Failure code [CA1633] KOMNET abnormality (Left bank): Communication error....................... 26
Failure code [CA2185] Throttle sensor supply voltage high error ............................................... 28
Failure code [CA2186] Throttle sensor power supply low error .................................................. 30
Failure code [CA2249] Loss of pressure feed from supply pump (2) (Left bank):
Loss of pressure feed detected ............................................................................................... 31
Failure code [CB2249] Loss of pressure feed from supply pump (2) (Right bank):
Loss of pressure feed detected ............................................................................................... 31
Failure code [CA2555] Intake heater relay voltage low error (Left bank) .................................... 32
Failure code [CA2556] Intake heater relay voltage high error (Left bank)................................... 34
00 Index and foreword SEN01276-12
HD785-7 11
Troubleshooting by failure code, Part 6 SEN01943-02
Failure code [D180KA] Preheating relay output system: Disconnection..................................... 3
Failure code [D180KB] Preheating relay output system: Grounding fault................................... 4
Failure code [D180KY] Preheating relay output system: Hot short circuit .................................. 6
Failure code [D19HKB] Stop lamp relay output system: Short circuit ......................................... 8
Failure code [D1EFKA] Pre-lubrication start relay output system: Disconnection....................... 10
Failure code [D1EFKB] Pre-lubrication start relay output system: Grounding fault .................... 12
Failure code [D1EFKY] Pre-lubrication start relay output system: Hot short circuit .................... 14
Failure code [DAF9KM] Wrong connection of connector ............................................................ 16
Failure code [DAFRKR] CAN communication error (Machine monitor): Communication error... 17
Failure code [DAQ0KK] Transmission controller direct power supply:
Lowering of source voltage......................................................................................................20
Failure code [DAQ0KT] Transmission controller nonvolatile memory:
Abnormality in controller .......................................................................................................... 22
Failure code [DAQ2KK] Transmission controller solenoid power source:
Power source voltage too low.................................................................................................. 23
Failure code [DAQ9KQ] Transmission controller: Disagreement of model selection .................. 24
Failure code [DAQRKR] Abnormality in CAN communication (Transmission)............................ 24
Failure code [DAQRMA] Transmission controller option setting: Malfunction............................. 25
Failure code [DB10KT] Retarder controller nonvolatile memory: Abnormality in controller ........ 25
Failure code [DB12KK] Retarder controller solenoid power source:
Power source system trouble .................................................................................................. 26
Failure code [DB13KK] Retarder controller battery direct power source:
Power source voltage too low.................................................................................................. 28
Failure code [DB19KQ] Disagreement of model selection (Retarder controller)......................... 30
Failure code [DB1RKR] CAN communication (retarder controller): Communication disabled.... 31
Failure code [DB1RMA] Disagreement of option setting (Retarder controller)............................ 34
Failure code [DB2RKR] CAN communication (engine controller): Communication disabled...... 35
Failure code [dB2RKR] CAN communication (engine controller): Communication disabled ...... 38
Failure code [DBB0KK] (or VHMS_LED display: "n9" o"01")
VHMS controller: Low source voltage (input) .......................................................................... 42
Failure code [DBB0KQ] (or VHMS_LED display: "nF" o"11")
(VHMS controller: Disagreement of model selection signals) ................................................. 44
Failure code [DBB3KK] (or VHMS_LED display: "n9" o"05")
VHMS controller battery power supply: Low source voltage (input) ........................................ 46
Failure code [DBB5KP] (or VHMS_LED display: "n9" o"04")
(VHMS controller 5 V power supply output: Low output voltage) ............................................ 48
Failure code [DBB6KP] (or VHMS_LED display: "n9" o"02")
(VHMS controller 24 V power supply output: Low output voltage) .......................................... 50
Failure code [DBB7KP] (or VHMS_LED display: "n9" o"03")
(VHMS controller 12 V power supply output: Low output voltage) .......................................... 52
Failure code [DBBQKR] (or VHMS_LED display: "n8" o"02") VHMS controller
CAN communication: Defective communication (Abnormality in target component system) .. 54
Failure code [DBBRKR] Abnormality in CAN communication (VHMS) ....................................... 56
Failure code [DBC2KK] ABS controller solenoid power source:
Power source system trouble .................................................................................................. 58
Failure code [DBC3KK] ABS controller battery direct power source:
Power source voltage too low.................................................................................................. 60
Failure code [DBC9KQ] Disagreement of model selection (ABS controller)............................... 62
Failure code [DBCRKR] Abnormality in CAN communication (ABS) .......................................... 62
Failure code [DBCRMA] Disagreement of option setting (ABS controller).................................. 63
Failure code [DBG2KK] Solenoid power supply: Low voltage .................................................... 64
Failure code [DBG3KK] Battery direct power supply: Low voltage ............................................. 66
Failure code [DBG9KQ] Model selection signal: Abnormal......................................................... 68
Failure code [DDD7KX] Trouble in travel speed setting switch system:
Out of input signal range ......................................................................................................... 70
Failure code [DDD8KA] ARSC system switch system: Disconnection ....................................... 72
Failure code [DDD8KB] ARSC system switch system: Short circuit ........................................... 74
SEN01276-12 00 Index and foreword
12 HD785-7
Failure code [DDD9KA] ABS system switch system: Disconnection .......................................... 76
Failure code [DDD9KB] ABS system switch system: Short circuit .............................................. 78
Failure code [DDDAKA] ASR system switch: Disconnection ...................................................... 80
Failure code [DDDAKB] ASR system switch: Short circuit.......................................................... 82
Failure code [DDE2KB] Engine oil pressure switch error: Grounding fault ................................. 84
Failure code [DDE2L6] Engine oil pressure switch error: Disconnection or hot short circuit ...... 86
Failure code [DDP6L4] Service brake pressure switch trouble (Rear)........................................ 88
Failure code [DDTHKA] Hi clutch fill switch: Disconnection ........................................................ 90
Failure code [DDTJKA] Lo clutch fill switch: Disconnection ........................................................ 92
Failure code [DDTKKA] 1st clutch fill switch: Disconnection....................................................... 94
Failure code [DDTLKA] 2nd clutch fill switch: Disconnection ...................................................... 96
Failure code [DDTMKA] 3rd clutch fill switch: Disconnection...................................................... 98
Failure code [DDTNKA] R clutch fill switch: Disconnection......................................................... 100
Failure code [DDTPKA] 4th clutch fill switch: Disconnection....................................................... 102
Failure code [DF10KA] Gear shift lever: Disconnection .............................................................. 104
Failure code [DF10KB] Gear shift lever: Short circuit.................................................................. 107
Failure code [DGE5KX] (or VHMS_LED display: "n4" o"01")
(Atmospheric temperature sensor: Out of input signal range) ................................................. 110
Failure code [DGF1KX] Transmission oil temperature sensor: Out of input signal range........... 112
Failure code [DGR2KB] Trouble in retarder oil temperature sensor (rear wheel) system
(Disconnection and short circuit) ............................................................................................. 114
Failure code [DGR2KZ] Trouble in retarder oil temperature sensor (rear wheel) system
(Ground fault)........................................................................................................................... 116
Failure code [DGR4KB] Trouble in retarder oil temperature sensor (front wheel) system
(Disconnection and short circuit) ............................................................................................. 118
Failure code [DGR4KZ] Trouble in retarder oil temperature sensor (front wheel) system
(Ground fault)........................................................................................................................... 120
Failure code [DGR6KX] Steering oil temperature sensor: Input signal out of range ................... 122
Failure code [DGT1KX] Torque converter oil temperature sensor: Out of input signal range ..... 124
Troubleshooting by failure code, Part 7 SEN01944-01
Failure code [DGT5KA] (or VHMS_LED display: "n3" o"12")
Left bank exhaust temperature sensor system (Front): Disconnection ................................... 3
Failure code [dGT5KA] (or VHMS_LED display: "n3" o"22")
Left bank exhaust temperature sensor system (Rear): Disconnection .................................... 6
Failure code [DGT5KB] (or VHMS_LED display: "n3" o"11")
Left bank exhaust temperature sensor system (Front): Short circuit ....................................... 9
Failure code [dGT5KB] (or VHMS_LED display: "n3" o"21")
Left bank exhaust temperature sensor system (Rear): Short circuit........................................ 12
Failure code [DGT6KA] (or VHMS_LED display: "n3" o"24")
Right bank exhaust temperature sensor system (Front): Disconnection ................................. 15
Failure code [dGT6KA] (or VHMS_LED display: "n3" o"26")
Right bank exhaust temperature sensor system (Rear): Disconnection.................................. 18
Failure code [DGT6KB] (or VHMS_LED display: "n3" o"23")
Right bank exhaust temperature sensor system (Front): Short circuit..................................... 21
Failure code [dGT6KB] (or VHMS_LED display: "n3" o"25")
Right bank exhaust temperature sensor system (Rear): Short circuit ..................................... 24
Failure code [DHE5KB] (or VHMS_LED display: "n3" o"32")
(Blow-by pressure sensor: Short circuit).................................................................................. 28
Failure code [DHE5KY] (or VHMS_LED display: "n3" o"31")
(Blow-by pressure sensor: Short circuit with power supply line).............................................. 30
Failure code [DHP4KY] (or VHMS_LED display: "n5" o"44")
Suspension pressure sensor system: Short circuit (Right front).............................................. 32
Failure code [DHP4KZ] (or VHMS_LED display: "n5" o"43")
Suspension pressure sensor system: Disconnection or ground fault (Right front) .................. 34
Failure code [DHP5KY] (or VHMS_LED display: "n5" o"54")
Suspension pressure sensor system: Short circuit (Left front) ................................................ 36
Failure code [DHP5KZ] (or VHMS_LED display: "n5" o"53")
Suspension pressure sensor system: Disconnection or ground fault (Left front) .................... 38
00 Index and foreword SEN01276-12
HD785-7 13
Failure code [DHP6KA] Suspension pressure sensor system: Disconnection (Right rear) ........ 40
Failure code [DHP6KX] Failure in suspension pressure sensor system trouble:
Out of input signal range (Right rear) ...................................................................................... 42
Failure code [DHP6KY] (or VHMS_LED display: "n5" o"64")
Suspension pressure sensor system: Short circuit (Right rear) .............................................. 44
Failure code [DHP6KZ] (or VHMS_LED display: "n5" o"63")
Suspension pressure sensor system: Disconnection or ground fault (Right rear)................... 46
Failure code [DHP7KA] Suspension pressure sensor system: Disconnection (Left rear)........... 48
Failure code [DHP7KX] Failure in suspension pressure sensor system:
Out of input signal range (Left rear)......................................................................................... 50
Failure code [DHP7KY] (or VHMS_LED display: "n5" o"74")
Suspension pressure sensor system: Short circuit (Left rear) ................................................. 52
Failure code [DHP7KZ] (or VHMS_LED display: "n5" o"73")
Suspension pressure sensor system: Disconnection or ground fault (Left rear) ..................... 54
Failure code [DHT5KX] Torque converter oil pressure sensor: Out of input signal range........... 56
Failure code [DHT5L6] Torque converter oil pressure sensor:
Disagreement of run and stop condition with signal ................................................................ 58
Failure code [DHU2KX] Front accumulator oil pressure sensor: Out of input signal range ........ 60
Failure code [DHU3KX] Rear accumulator oil pressure sensor: Out of input signal range......... 62
Failure code [DHU6KX] Trouble in ABS control valve pressure sensor (Front right) .................. 64
Failure code [DHU7KX] Trouble in ABS control valve pressure sensor (Front left) .................... 66
Failure code [DHU8KX] Trouble in ABS control valve pressure sensor (Rear right)................... 68
Failure code [DHU9KX] Trouble in ABS control valve pressure sensor (Rear left)..................... 70
Failure code [DJF1KA] Fuel level sensor: Disconnection ........................................................... 72
Failure code [DK30KX] Steering angle potentiometer: Trouble (Disconnection)......................... 73
Failure code [DK51L5] Trouble in retarder lever potentiometer and RVS................................... 74
Failure code [DK52KX] Failure in hoist lever potentiometer 1: Out of input signal range ........... 78
Failure code [DK53L8] Failure in hoist lever potentiometer 2: Disagreement of analog signal... 80
Failure code [DK54KX] Body positioner sensor: Out of input signal range................................. 82
Failure code [DKD0L6] Failure in steering angle speed sensor.................................................. 84
Failure code [DKH0KX] Pitch angle sensor: Out of input signal range ....................................... 86
Failure code [DKH1KX] (or VHMS_LED display: "n4" o"33") Pitch angle sensor:
Abnormality.............................................................................................................................. 88
Failure code [DLF1KA] Transmission input shaft speed sensor: Disconnection......................... 90
Failure code [DLF1LC] Transmission input shaft speed sensor:
Disagreement of revolution speed signal ................................................................................ 92
Failure code [DLF2KA] Transmission intermediate shaft speed sensor: Disconnection............. 94
Failure code [DLF2LC] Transmission intermediate shaft speed sensor:
Disagreement of revolution speed signal ................................................................................ 96
Troubleshooting by failure code, Part 8 SEN01945-02
Failure code [DLF6KA] Disconnection in wheel speed sensor (Front right)................................ 4
Failure code [DLF6L3] Trouble in wheel speed sensor (Front right) ........................................... 6
Failure code [DLF7KA] Disconnection in wheel speed sensor (Front left).................................. 8
Failure code [DLF7L3] Trouble in wheel speed sensor (Front left) ............................................. 10
Failure code [DLF8KA] Wheel speed sensor: Disconnection (Rear right) .................................. 12
Failure code [DLF8L3] Wheel speed sensor: Disconnection (Rear right) ................................... 14
Failure code [DLF8LC] Wheel speed sensor: Trouble (Rear right) ............................................. 16
Failure code [DLF8MA] Wheel speed sensor: Disconnection (Rear right).................................. 16
Failure code [DLF9KA] Wheel speed sensor: Disconnection (Rear left) .................................... 18
Failure code [DLF9L3] Wheel speed sensor: Trouble (Rear left)................................................ 20
Failure code [DLF9LC] Wheel speed sensor: Trouble (Rear left) ............................................... 22
Failure code [DLF9MA] Wheel speed sensor: Disconnection (Rear left).................................... 22
Failure code [DLT3KA] Transmission output shaft speed sensor: Disconnection ....................... 24
Failure code [DLT3LC] Transmission output shaft speed sensor:
Disagreement of revolution speed signal ................................................................................ 26
Failure code [DLT4KA] Transmission output shaft speed sensor: Disconnection ....................... 28
Failure code [DLT4MA] Transmission output shaft speed sensor: Disconnection ...................... 30
Failure code [DUM7KY] Pre-lubrication operation lamp output abnormality: Hot short circuit .... 32
SEN01276-12 00 Index and foreword
14 HD785-7
Failure code [DUM7KZ] Pre-lubrication operation lamp output abnormality:
Disconnection or grounding fault ............................................................................................. 34
Failure code [DV00KB] Buzzer output: Short circuit.................................................................... 36
Failure code [DW2AKA] Main pressure variable valve output: Disconnection ............................ 38
Failure code [DW2AKB] Main pressure variable valve output circuit: Ground fault .................... 40
Failure code [DW2AKY] Main pressure variable valve output circuit: Hot short.......................... 42
Failure code [DW2AL1] Main pressure variable valve: Defective reset ...................................... 44
Failure code [DW2ALH] Main pressure variable valve: Malfunction ........................................... 46
Failure code [DW2BKA] Main oil level selector valve output: Disconnection .............................. 47
Failure code [DW2BKB] Main oil level selector valve output circuit: Ground fault ...................... 48
Failure code [DW2BKY] Main oil level selector valve output circuit: Hot short............................ 50
Failure code [DW2BL1] Main oil level selector valve: Defective reset ........................................ 52
Failure code [DW2BLH] Main oil level selector valve: Malfunction ............................................. 54
Failure code [DW2CKA] Transmission lubrication variable valve output: Disconnection ............ 55
Failure code [DW2CKB] Transmission lubrication variable valve output circuit: Ground fault .... 56
Failure code [DW2CKY] Transmission lubrication variable valve output circuit: Hot short.......... 58
Failure code [DW2CL1] Transmission lubrication variable valve: Defective reset ...................... 60
Failure code [DW2CLH] Transmission lubrication variable valve: Malfunction ........................... 62
Failure code [DW35KZ] Failure in output system of auto suspension solenoid 1:
Disconnection or short circuit................................................................................................... 64
Failure code [DW36KZ] Failure in output system of auto suspension solenoid 2:
Disconnection or short circuit................................................................................................... 66
Failure code [DW71KZ] Exhaust brake output system trouble
(Disconection/Ground fault/Hot short) ..................................................................................... 68
Failure code [DW72KZ] Kick-out solenoid output system trouble:
Disconnection or short circuit................................................................................................... 70
Failure code [DW73KZ] Failure in hoist select valve output system:
Disconnection or short circuit................................................................................................... 72
Failure code [DW78KZ] Brake cooling valve (BCV) (rear wheel) output system trouble:
Disconnection or short circuit................................................................................................... 74
Failure code [DWNBK4] ASR shut-off valve: Trouble (Valve keeps operating)........................... 76
Failure code [DWNBKA] ASR shut-off valve output circuit: Disconnection ................................. 78
Failure code [DWNBKB] ASR shut-off valve output circuit: Ground fault.................................... 80
Failure code [DWNBKY] ASR shut-off valve output circuit: Short circuit..................................... 82
Failure code [DWNBMA] ASR shut-off valve: Trouble (Valve does not operate) ........................ 82
Failure code [DWNDKZ] Trouble in ABS cut-off valve (Front) system ........................................ 84
Failure code [DWNDMA] Defective ABS cut-off valve (Front)..................................................... 86
Failure code [DWNEKZ] Trouble in ABS cut-off valve (Rear) system ......................................... 88
Failure code [DWNEMA] Defective ABS cut-off valve (Rear) ..................................................... 90
Troubleshooting by failure code, Part 9 SEN01946-02
Failure code [DX11K4] Rear brake proportional pressure reducing solenoid valve:
Out of control ........................................................................................................................... 4
Failure code [DX11KA] Rear brake proportional pressure reducing solenoid valve output circuit:
Disconnection .......................................................................................................................... 6
Failure code [DX11KB] Rear brake proportional pressure reducing solenoid valve:
Short circuit.............................................................................................................................. 7
Failure code [DX11KY] Rear brake proportional pressure reducing solenoid valve:
Short circuit to power source line............................................................................................. 8
Failure code [DX11MA] Rear brake proportional pressure reducing solenoid valve:
Malfunction .............................................................................................................................. 10
Failure code [DX12K4] Front brake proportional pressure reducing solenoid valve:
Out of control ........................................................................................................................... 12
Failure code [DX12KA] Front brake proportional pressure reducing solenoid valve output circuit:
Disconnection .......................................................................................................................... 14
Failure code [DX12KB] Front brake proportional pressure reducing solenoid valve:
Short circuit.............................................................................................................................. 15
Failure code [DX12KY] Front brake proportional pressure reducing solenoid valve:
Short circuit to power source line............................................................................................. 16
00 Index and foreword SEN01276-12
HD785-7 15
Failure code [DX12MA] Front brake proportional pressure reducing solenoid valve:
Malfunction .............................................................................................................................. 18
Failure code [DX13KA] Output circuit of hoist EPC valve: Disconnection .................................. 20
Failure code [DX13KB] Output circuit of hoist EPC valve: Short circuit ...................................... 22
Failure code [DX13KY] Output circuit of hoist EPC valve: Short circuit with power source line .... 24
Failure code [DX17K4] ASR proportional pressure reducing solenoid valve (right):
Trouble (Valve keeps operating).............................................................................................. 26
Failure code [DX17KA] ASR proportional pressure reducing solenoid valve (right) output circuit:
Disconnection .......................................................................................................................... 28
Failure code [DX17KB] ASR proportional pressure reducing solenoid valve (right) output circuit:
Ground fault............................................................................................................................. 30
Failure code [DX17KY] ASR proportional pressure reducing solenoid valve (right) output circuit:
Short circuit.............................................................................................................................. 32
Failure code [DX17MA] ASR proportional pressure reducing solenoid valve (right):
Trouble (Valve does not operate) ............................................................................................ 32
Failure code [DX18K4] ASR proportional pressure reducing solenoid valve (left):
Trouble (Valve keeps operating).............................................................................................. 34
Failure code [DX18KA] ASR proportional pressure reducing solenoid valve (left) output circuit:
Disconnection .......................................................................................................................... 36
Failure code [DX18KB] ASR proportional pressure reducing solenoid valve (left) output circuit:
Ground fault............................................................................................................................. 38
Failure code [DX18KY] ASR proportional pressure reducing solenoid valve (left) output circuit:
Short circuit.............................................................................................................................. 40
Failure code [DX18MA] ASR proportional pressure reducing solenoid valve (left):
Trouble (Valve does not operate) ............................................................................................ 40
Failure code [DX21KA] Disconnection in ABS control valve output circuit (Front right).............. 41
Failure code [DX21KB] Ground fault in ABS control valve output circuit (Front right) ................ 42
Failure code [DX21KY] Hot short in ABS control valve output circuit (Front right)...................... 43
Failure code [DX21MA] Defective ABS control valve (Front right).............................................. 44
Failure code [DX22KA] Disconnection in ABS control valve output circuit (Front left)................ 45
Failure code [DX22KB] Ground fault in ABS control valve output circuit (Front left)................... 46
Failure code [DX22KY] Hot short in ABS control valve output circuit (Front left) ........................ 47
Failure code [DX22MA] Defective ABS control valve (Front left) ................................................ 48
Failure code [DX23KA] Disconnection in ABS control valve output circuit (Rear right) .............. 49
Failure code [DX23KB] Ground fault in ABS control valve output circuit (Rear right) ................. 50
Failure code [DX23KY] Hot short in ABS control valve output circuit (Rear right) ...................... 51
Failure code [DX23MA] Defective ABS control valve (Rear right) .............................................. 52
Failure code [DX24KA] Disconnection in ABS control valve output circuit (Rear left)................. 53
Failure code [DX24KB] Ground fault in ABS control valve output circuit (Rear left) ................... 54
Failure code [DX24KY] Hot short in ABS control valve output circuit (Rear left) ........................ 55
Failure code [DX24MA] Defective ABS control valve (Rear left)................................................. 56
Failure code [DX25MA] Defective ABS front wheel system control valve................................... 57
Failure code [DX26MA] Defective ABS rear wheel system control valve ................................... 57
Troubleshooting by failure code, Part 10 SEN01947-01
Failure code [DXH1KA] Lockup clutch solenoid output circuit: Disconnection............................ 3
Failure code [DXH1KB] Lock-up clutch solenoid output circuit: Short circuit .............................. 4
Failure code [DXH1KY] Lockup clutch solenoid output circuit:
Short circuit to power source line ............................................................................................ 5
Failure code [DXH2KA] Hi clutch solenoid output circuit: Disconnection.................................... 6
Failure code [DXH2KB] Hi clutch solenoid output circuit: Short circuit ....................................... 8
Failure code [DXH2KY] Hi clutch solenoid output circuit: Short circuit to power source line ...... 10
Failure code [DXH3KA] Lo clutch solenoid output circuit: Disconnection ................................... 14
Failure code [DXH3KB] Lo clutch solenoid output circuit: Short circuit....................................... 16
Failure code [DXH3KY] Lo clutch solenoid output circuit: Short circuit in power source line...... 18
Failure code [DXH4KA] 1st clutch solenoid output circuit: Disconnection .................................. 22
Failure code [DXH4KB] 1st clutch solenoid output circuit: Short circuit ...................................... 24
Failure code [DXH4KY] 1st clutch solenoid output circuit: Short circuit to power source line..... 26
Failure code [DXH5KA] 2nd clutch solenoid output circuit: Disconnection ................................. 30
SEN01276-12 00 Index and foreword
16 HD785-7
Failure code [DXH5KB] 2nd clutch solenoid output circuit: Short circuit ..................................... 32
Failure code [DXH5KY] 2nd clutch solenoid output circuit: Short circuit in power source line .... 34
Failure code [DXH6KA] 3rd clutch solenoid output circuit: Disconnection .................................. 38
Failure code [DXH6KB] 3rd clutch solenoid output circuit: Short circuit...................................... 40
Failure code [DXH6KY] 3rd clutch solenoid output circuit: Short circuit to power source line..... 42
Failure code [DXH7KA] R clutch solenoid output circuit: Disconnection..................................... 46
Failure code [DXH7KB] R clutch solenoid output circuit: Short circuit ........................................ 48
Failure code [DXH7KY] R clutch solenoid output circuit: Short circuit to power source line ....... 50
Failure code [DXHHKA] 4th clutch solenoid output circuit: Disconnection.................................. 52
Failure code [DXHHKB] 4th clutch solenoid output circuit: Short circuit ..................................... 54
Failure code [DXHHKY] 4th clutch solenoid output circuit: Short circuit to power source line .... 56
Failure code [F@BBZL] (or VHMS_LED display: "n3" o"38")
(Blow-by pressure: High error)................................................................................................. 60
Failure code [F@BYNS] (or VHMS_LED display "n3" o"61")
Left front exhaust temperature sensor (1): Exhaust temperature abnormal rise ..................... 62
Failure code [f@BYNS] (or VHMS_LED display "n3" o"71")
Left rear exhaust temperature sensor (1): Exhaust temperature abnormal rise ...................... 64
Failure code [F@BZNS] (or VHMS_LED display "n3" o"81")
Right front exhaust temperature sensor (1): Exhaust temperature abnormal rise................... 66
Failure code [f@BZNS] (or VHMS_LED display "n3" o"91")
Right rear exhaust temperature sensor (1): Exhaust temperature abnormal rise.................... 68
Failure code [F@BYNR] (or VHMS_LED display "n3" o"62")
Left front exhaust temperature sensor (2): Exhaust temperature abnormal rise ..................... 70
Failure code [f@BYNR] (or VHMS_LED display "n3" o"72")
Left rear exhaust temperature sensor (2): Exhaust temperature abnormal rise ...................... 72
Failure code [F@BZNR] (or VHMS_LED display "n3" o"82")
Right front exhaust temperature sensor (2): Exhaust temperature abnormal rise................... 74
Failure code [f@BZNR] (or VHMS_LED display "n3" o"92")
Right rear exhaust temperature sensor (2): Exhaust temperature abnormal rise.................... 76
Troubleshooting of electrical system (E-mode) SEN01948-03
Before troubleshooting of electric system ................................................................................... 3
Contents of troubleshooting table................................................................................................ 4
E-1 Engine does not start............................................................................................................ 5
E-2 Automatic preheating does not operate................................................................................ 8
E-3 Machine monitor does not display all, when starting switch is turned ON ............................ 12
E-4 Machine monitor does not operate when starting switch is OFF .......................................... 14
E-5 Alarm buzzer does not sound ............................................................................................... 16
E-6 Alarm buzzer does not stop sounding .................................................................................. 18
E-7 Gauges of machine monitor, caution lamps or character display section
do not display properly............................................................................................................. 19
E-8 A selection of the display in character display section cannot be changed .......................... 21
E-9 Power mode selecting function does not operate properly................................................... 24
E-10 AISS function does not operate properly ............................................................................ 25
E-11 Seat belt caution lamp does not display properly ............................................................... 26
E-12 Turn signal lamp or turning lamp (hazard lamp) do not work properly................................ 27
E-13 Night illumination (lighting) does not work properly ............................................................ 30
E-14 Emergency steering does not operate................................................................................ 42
E-15 Hoist lever does not operate normally ................................................................................ 48
E-16 Power supply system (Air conditioner does not operate) ................................................... 50
E-17 Compressor and refrigerant system (Air is not cooled) ...................................................... 52
E-18 Blower motor system (Air does not come out or air flow is abnormal)................................ 54
Troubleshooting of hydraulic and mechanical system (H-mode) SEN01949-01
Contents of troubleshooting table................................................................................................ 3
H-1 Machine does not start ......................................................................................................... 4
H-2 Machine does not travel smoothly (hunting)......................................................................... 6
H-3 Lockup cannot be cancelled ................................................................................................. 6
H-4 Excessive shock when starting or shifting excessive ........................................................... 7
00 Index and foreword SEN01276-12
HD785-7 17
H-5 Transmission does not shift up............................................................................................. 8
H-6 Machine lacks power or speed when traveling..................................................................... 10
H-7 Time lag is excessive when starting or shifting gear ............................................................ 14
H-8 Torque converter oil temperature is high .............................................................................. 16
H-9 Torque converter oil pressure is low..................................................................................... 17
H-10 Front brake is ineffective .................................................................................................... 18
H-11 Rear brake is ineffective ..................................................................................................... 19
H-12 Steering wheel is heavy...................................................................................................... 20
H-13 Steering wheel does not work ............................................................................................ 21
H-14 Steering wheel vibrates ...................................................................................................... 22
H-15 Dump body lifting speed is slow ......................................................................................... 23
H-16 Dump body does not work.................................................................................................. 24
H-17 Excessive hydraulic drift of dump body .............................................................................. 25
Troubleshooting of engine (S-mode) SEN01950-01
Method of using troubleshooting charts ...................................................................................... 3
S-1 Starting performance is poor ................................................................................................6
S-2 Engine does not start............................................................................................................ 7
S-3 Engine does not pick up smoothly........................................................................................ 10
S-4 Engine stops during operations ............................................................................................ 11
S-5 Engine does not rotate smoothly .......................................................................................... 12
S-6 Engine lacks output (or lacks power).................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion)................................................................ 15
S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................... 16
S-9 Oil becomes contaminated quickly ....................................................................................... 17
S-10 Fuel consumption is excessive........................................................................................... 18
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................. 19
S-12 Oil pressure drops .............................................................................................................. 20
S-13 Oil level rises (Entry of coolant or fuel)............................................................................... 21
S-14 Coolant temperature becomes too high (overheating) ....................................................... 22
S-15 Abnormal noise is made .....................................................................................................23
S-16 Vibration is excessive ......................................................................................................... 24
50 Disassembly and assembly
General information on disassembly and assembly SEN01951-03
How to read this manual ............................................................................................................. 2
Coating materials list................................................................................................................... 4
Special tool list ............................................................................................................................ 7
Sketches of special tools............................................................................................................. 10
Engine and cooling system SEN01952-02
Removal and installation of fuel supply pump assembly............................................................. 2
Removal and installation of fuel injector assembly ..................................................................... 4
Removal and installation of cylinder head assembly .................................................................. 5
Removal and installation of engine hood assembly .................................................................... 18
Removal and installation of radiator assembly............................................................................ 19
Removal and installation of engine assembly ............................................................................. 28
Removal and installation of engine front oil seal......................................................................... 33
Removal and installation of engine rear oil seal.......................................................................... 36
Power train, Part 1 SEN01953-02
Removal and installation of front drive shaft ............................................................................... 2
Removal and installation of rear drive shaft ................................................................................ 4
Removal and installation of output shaft assembly ..................................................................... 5
Disassembly and assembly of damper assembly ....................................................................... 10
Removal and installation of torque converter and transmission assembly ................................. 12
Disconnection and connection of torque converter assembly and transmission assembly ........ 15
Disassembly and assembly of torque converter PTO assembly................................................. 22
Disassembly and assembly of transmission assembly ............................................................... 35
SEN01276-12 00 Index and foreword
18 HD785-7
Power train, Part 2 SEN02106-03
Removal and installation of final drive carrier assembly ............................................................. 2
Disassembly and assembly of final drive carrier assembly ......................................................... 4
Removal and installation of differential assembly........................................................................ 6
Disassembly and assembly of differential assembly ................................................................... 9
Steering system SEN04641-00
Removal and installation of steering cylinder assembly.............................................................. 2
Disassembly and assembly of steering cylinder assembly ......................................................... 3
Removal and installation of steering valve assembly.................................................................. 7
Disassembly and assembly of steering valve assembly ............................................................. 8
Brake system SEN04642-01
Removal and installation of front wheel hub and brake assembly .............................................. 2
Disassembly and assembly of front wheel hub and brake assembly .......................................... 6
Removal and installation of final drive and rear brake assembly ................................................ 14
Disassembly and assembly of final drive and rear brake assembly............................................ 16
Undercarriage and frame SEN04643-01
Removal and installation of front wheel assembly ...................................................................... 2
Removal and installation of rear wheel assembly ....................................................................... 4
Removal and installation of front suspension cylinder assembly ................................................ 6
Disassembly and assembly of front suspension cylinder assembly (cylinder with buffer ring) ... 8
Removal and installation of king pin............................................................................................11
Removal and installation of rear suspension cylinder assembly ................................................. 13
Disassembly and assembly of rear suspension cylinder assembly............................................. 14
Hydraulic system SEN04644-00
Removal and installation of hoist valve assembly ....................................................................... 2
Disassembly and assembly of hoist valve assembly................................................................... 3
Disassembly and assembly of hoist cylinder assembly............................................................... 5
Body SEN04645-00
Removal and installation of body assembly ................................................................................ 2
Cab and its attachments SEN04646-00
Disassembly and assembly of operator's seat assembly............................................................ 2
Removal and installation of air conditioner unit assembly........................................................... 12
Electrical system SEN04647-01
Removal and installation of engine controller assembly ............................................................. 2
Removal and installation of transmission controller assembly .................................................... 2
Removal and installation of retarder controller assembly............................................................ 3
Removal and installation of ABS controller assembly ................................................................. 3
Removal and installation of VHMS controller assembly.............................................................. 4
90 Diagrams and drawings
Hydraulic diagrams and drawings SEN01298-03
Power train hydraulic circuit diagram .......................................................................................... 3
Steering and hoist hydraulic circuit diagram................................................................................ 5
Brake hydraulic circuit diagram ................................................................................................... 7
Brake hydraulic circuit diagram (ASR specification).................................................................... 9
Brake hydraulic circuit diagram (ABS specification).................................................................... 11
Brake hydraulic circuit diagram (ASR and ABS specification) .................................................... 13
Electrical diagrams and drawings SEN01299-06
Electrical circuit diagram for outside cab (1/3) ............................................................................ 3
Electrical circuit diagram for outside cab (2/3) ............................................................................ 5
Electrical circuit diagram for outside cab (3/3) ............................................................................ 7
Electrical circuit diagram for inside cab (1/3)............................................................................... 9
Electrical circuit diagram for inside cab (2/3)............................................................................... 11
Electrical circuit diagram for inside cab (3/3)............................................................................... 13
Electrical circuit diagram for VHMS (If equipped)........................................................................ 15
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