Komatsu DUMP TRUCK HD785-7 Shop Manual SEN05900-22 – PDF DOWNLOAD

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Komatsu DUMP TRUCK HD785-7 Shop Manual SEN05900-22 – PDF DOWNLOAD

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Komatsu DUMP TRUCK HD785-7 Shop Manual SEN05900-22 – PDF DOWNLOAD

Language : English
Pages :2318
Downloadable : Yes
File Type : PDF

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Komatsu DUMP TRUCK HD785-7 Shop Manual SEN05900-22 – PDF DOWNLOAD

SERIAL NUMBERS 30001 and up

Foreword and general information
Safety notice
Important safety notice

• Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop manuals describe the effective and safe servicing and repair methods recommended by Komatsu. Some of the servicing and repair methods require use of special tools designed by Komatsu for special purposes. The symbol mark “k” is indicated for such matters that require special precautions.
• The work indicated with the warning mark should be performed according to the instructions with special attention to the precautions. Should a hazardous situation occur or be anticipated during such work, be sure to keep safe first and take every necessary measure.

1. General precautions 

Inappropriate handling creates an extreme danger. Read and understand what is described in the Operation and Maintenance Manual before operating the machine. Read and understand what is described in this manual before starting work.

TABLE OF CONTENTS:

Komatsu DUMP TRUCK HD785-7 Shop Manual SEN05900-22 – PDF DOWNLOAD’

SERIAL NUMBERS 30001 and up

Cover 1
00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword and general information 25
Safety notice 26
How to read the shop manual 32
Explanation of terms for maintenance standard 34
Handling of hydraulic components 36
Method of disconnecting and connecting push-pull type coupler 38
Handling of electric equipment 41
How to read electric wire code 51
Precautions when performing work 54
Standard tightening torque table 57
List of Abbreviation 61
Conversion table 65
01 Specification 71
Specification and technical data 71
Specification drawing 72
Specifications 74
Weight table 77
Fuel, coolant and lubricants 78
10 Structure, function and maintenance standard 83
Engine and cooling system 83
Radiator, brake, torque converter oil cooler, aftercooler, steering, hoist oil cooler 84
Fuel system 86
Power train, Part 1 89
Power train skeleton 90
Output shaft 92
Drive shaft 94
Torque converter and transmission hydraulic piping 96
Brake cooling oil control valve (BCV) 98
Torque converter 100
Torque converter valve 107
Transmission 110
Transmission control valve 138
ECMV 140
Power train, Part 2 151
Axle 152
Differential 154
Final drive 155
Wheels 156
Steering system 159
Steering column 160
Steering linkage 161
Brake system 165
Brake piping 166
Brake valve 168
Secondary brake valve 171
Accumulator charge valve 172
Accumulator 177
Slack adjuster 179
Brake, parking brake 183
Parking brake solenoid 189
Retarder control valve 190
Exhaust brake (If equipped) 191
Undercarriage and frame 195
Suspension 196
Suspension cylinder 198
Rear axle support 206
Hydraulic system 209
Steering and hoist hydraulic piping 210
Steering, hoist filter (high pressure circuit) 212
Dump body control 214
Power ladder system (If equipped) 216
Hydraulic tank 222
Steering valve 223
Crossover relief valve 227
Steering cylinder 228
Steering control valve 229
Hoist valve 238
Dump control valve (EPC valve) 244
Hydraulic pump 246
Work equipment (Body) 251
Auto greasing system (If equipped) 252
Buddy system (if equipped) 263
Hoist cylinder 265
Cab and its attachments 267
ROPS cab 268
Air conditioner (If equipped) 269
Rear view monitor system (If equipped) 278
Controller related 283
Electrical system, Part 1 285
Machine monitor system 286
Electrical system, Part 2 311
Automatic shift control system 312
External power supply heater 332
Automatic emergency steering system 334
Automatic suspension system 338
Retarder control system 341
Dump control lever 354
Ladder control function (If equipped) 358
Electrical system, Part 3 361
VHMS controller related 362
ABS/ASR system (If equipped) 388
Komatsu traction control system (KTCS) 406
Altitude setting function 408
Speed limit function (If equipped) 411
Electrical system, Part 4 417
Sensors, switches 418
Electrical system, Part 5 437
Mobile communication terminal (if equipped) 438
iTrack II system (if equipped) 442
20 Standard value table 447
Standard service value table 447
Standard value table for engine 448
Standard value table for machine 450
30 Testing and adjusting 463
Testing and adjusting, Part 1 463
Precautions before work 465
Testing and adjusting tools list 466
Sketch of special tool 472
Testing engine speed 473
Testing air supply pressure (boost pressure) 474
Testing exhaust temperature 476
Testing exhaust gas color 478
Adjustment of valve clearance 480
Testing compression pressure 482
Testing blow-by pressure 484
Testing engine oil pressure 485
Handling of fuel system devices 486
Releasing residual pressure from fuel system 486
Testing fuel pressure 487
Reduced cylinder mode operation 488
No-injection cranking 488
Testing leakage-from pressure limiter and return rate from injector 489
Bleeding air from fuel circuit (Standard spec) 492
Bleeding air from fuel circuit (Extra low-grade fuel spec) 496
Testing the fuel circuit for leakage 498
Replacement and adjustment of fan belt 499
Testing and adjusting alternator belt tension 500
Testing and adjusting air conditioner compressor belt 501
Testing and adjusting, Part 2 503
Testing torque converter stall speed 505
Testing and adjusting brake oil pressure 516
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas 519
Testing brake performance 527
Releasing remaining pressure in brake circuit 529
Bleeding air from brake circuit 530
Bleeding air from ASR circuit (if equipped) 532
Testing wear of front brake disc 533
Testing wear of rear brake disc 534
Method of releasing parking brake in an emergency 535
Testing and adjusting front suspension cylinder 536
Testing and adjusting rear suspension cylinder 540
Testing and adjusting front suspension cylinder (Automatic suspension specification) 544
Testing and adjusting hydraulic pressure in steering, hoist circuit 545
Testing and adjusting oil pressure in dump EPC circuit 548
Air bleeding from steering cylinder 549
Procedure for raising dump body in emergency 550
How to dump load from failed machine by using buddy system (if equipped) 551
Adjusting body positioner sensor 554
Resetting method for dump body seating control 556
Adjustment of tilt lock lever of steering wheel 557
Handling of high voltage circuit of engine controller 558
Adjusting transmission controller 558
Method for emergency escape at electrical system failure 559
Testing and adjusting ladder potentiometer 563
Calibration method of ladder position 564
Testing and adjusting, Part 3 567
Setting and adjusting of devices 568
Testing and adjusting, Part 4 583
Special functions of machine monitor (EMMS) 584
Testing and adjusting, Part 5 655
Opening ORBCOMM terminal 656
VHMS controller initial setting procedure (Setting method with VHMS tool) 658
VHMS controller initial setting procedure (Setting method with KOMTRAX
Plus PC tool) 683
Download data from VHMS controller (Download method with KOMTRAX Plus PC tool) 685
Precautions for replacing VHMS controller 687
Pm Clinic check sheet 693
Initial setting of payload meter 697
Setting of payload meter built in VHMS 698
Testing and adjusting, Part 6 707
Setting of mobile communication terminal 708
Battery disconnect switch 718
40 Troubleshooting 721
Failure code table and fuse locations 721
Failure codes table 722
Fuse locations 738
General information on troubleshooting 745
Precautions before work 746
Points to remember when troubleshooting 747
Sequence of events in troubleshooting 748
Check before troubleshooting 749
Classification and procedures for troubleshooting 750
Contents of troubleshooting table 751
Connector list and layout 753
Connection table for connector pin numbers 775
T- branch box and T- branch adapter table 811
Troubleshooting by failure code, Part 1 815
Failure code [1500L0] Dual engagement 817
Failure code [15B0NX] Transmission oil filter: Clogging 818
Failure code [15F0KM] R → F shifting abuse 1: Mistake in operation 820
Failure code [15F0MB] R → F shifting abuse 2: Mistake in operation 820
Failure code [15F7KM] Forward clutch disk abuse: Mistake in operation or setting 821
Failure code [15G0MW] R clutch: Slipping 822
Failure code [15G7KM] Reverse clutch disk abuse: Mistake in operation or setting 824
Failure code [15H0MW] Hi clutch: Slipping 826
Failure code [15J0MW] Lo clutch: Slipping 828
Failure code [15K0MW] 1st clutch: Slipping 830
Failure code [15L0MW] 2nd clutch: Slipping 832
Failure code [15M0MW] 3rd clutch: Slipping 834
Failure code [15N0MW] 4th clutch: Slipping 836
Failure code [15SBL1] R clutch solenoid: Fill signal is ON when command current is OFF 838
Failure code [15SBMA] R clutch solenoid: Malfunction 840
Failure code [15SCL1] Hi clutch solenoid: Fill signal is ON when command current is OFF 842
Failure code [15SCMA] Hi clutch solenoid: Malfunction 845
Failure code [15SDL1] Lo clutch solenoid: Fill signal is ON when command current is OFF 846
Failure code [15SDMA] Lo clutch solenoid: Malfunction 849
Failure code [15SEL1] 1st clutch solenoid: Fill signal is ON when command current is OFF 850
Failure code [15SEMA] 1st clutch solenoid: Malfunction 853
Troubleshooting by failure code, Part 2 855
Failure code [15SFL1] 2nd clutch solenoid: Fill signal is ON when command current is OFF 858
Failure code [15SFMA] 2nd clutch solenoid: Malfunction 861
Failure code [15SGL1] 3rd clutch solenoid: Fill signal is ON when command current is OFF 862
Failure code [15SGMA] 3rd clutch solenoid: Malfunction 865
Failure code [15SHL1] 4th clutch solenoid: Fill signal is ON when command current is OFF 866
Failure code [15SHMA] 4th clutch solenoid: Malfunction 869
Failure code [15SJMA] Lockup clutch solenoid: Malfunction 870
Failure code [2F00KM] Parking brake: Mistake in operation or setting 872
Failure code [2G42ZG] Accumulator: Oil pressure reduction (Front) 877
Failure code [2G43ZG] Accumulator: Oil pressure reduction (Rear) 877
Failure code [989A00] Engine over run prevention command signal: Operating 878
Failure code [989D00] Rear section tipping over alarm: Alarm is activated 878
Failure code [989X00] Overspeed alarm: Alarm operation 879
Failure code [989Y00] Overload alarm: Speed limit function operation 879
Failure code [989Z00] Parking Brake Interlock Caution 880
Failure code [A570NX] Engine oil filter: Clogging 882
Failure code [AA10NX] Air cleaner element: Clogging 884
Failure code [AB00L4] Alternator: Failure on battery charge circuit (R terminal signal is present and engine is stopped) 886
Failure code [AB00MA] Alternator: Malfunction 888
Failure code [AB00MB] Alternator: Failure on battery charge circuit (Absence of R terminal signal and detection error) 890
Failure code [B@BAZG] Abnormal lowering of engine oil pressure: Lowering of oil pressure 892
Failure code [B@BAZK] Engine oil: Level too low 894
Failure code [B@BCNS] Engine: Overheat 896
Failure code [B@BCZK] Lowering of radiator coolant: Lowering of level 898
Failure code [B@BFZK] Lowering of fuel level 900
Failure code [B@C6NS] Brake cooling oil: Overheating (Front) 901
Failure code [B@C7NS] Brake cooling oil: Overheating (Rear) 902
Failure code [B@CENS] Overheating of torque converter oil 904
Failure code [B@GAZK] Battery electrolyte level: Lowering of level 905
Failure code [B@JANS] Steering oil temperature: Overheat 906
Troubleshooting by failure code, Part 3 909
Failure code [CA111] Engine controller (Left bank): Internal abnormality1 912
Failure code [CB111] Engine controller (Right bank): Internal abnormality 914
Failure code [CA115] Abnormal engine Ne and Bkup speed sensors (Left bank): Abnormal speed sensor signal 916
Failure code [CB115] Abnormal engine Ne and Bkup speed sensors (Right bank): Abnormal speed sensor signal 917
Failure code [CA122] Charge pressure sensor too high (At left bank only): Excessively high voltage detected 918
Failure code [CA123] Charge pressure sensor too low (At left bank only): Excessively low voltage detected 920
Failure code [CA131] Throttle sensor high error (At left bank only) 922
Failure code [CA132] Throttle sensor low error (At left bank only) 924
Failure code [CA135] Oil pressure sensor too high (At left bank only):Excessively high voltage detected 926
Failure code [CA141] Oil pressure sensor too low (At left bank only):Excessively low voltage detected 928
Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected 930
Failure code [CA145] Coolant temperature sensor too low (At left bank only): Excessively low voltage detected 932
Failure code [CA153] Charge temperature sensor too high (At left bank only): Excessively high voltage detected 934
Failure code [CA154] Charge temperature sensor too low (At left bank only): Excessively low voltage detected 936
Failure code [CA187] Sensor power supply (2) abnormally low level (Left bank): Low voltage detection 938
Failure code [CB187] Sensor power supply (2) abnormally low level (Right bank): Low voltage detection 938
Failure code [CA212] Engine oil temperature sensor abnormally high level (At left bank only): High voltage detection 940
Failure code [CA213] Engine oil temperature sensor abnormally low level (At left bank only): Low voltage detection 942
Failure code [CA221] Atmospheric pressure sensor too high (At left bank only): Excessively high voltage detected 944
Failure code [CA222] Atmospheric pressure sensor too low (At left bank only): Excessively low voltage detected 946
Failure code [CA227] Sensor power source (2) too high (Left bank): Excessively high voltage detected 948
Failure code [CB227] Sensor power supply (2) abnormally high level (Right bank): High voltage detection 950
Failure code [CA234] Engine over speed (At left bank only): Excessively high speed 952
Failure code [CA238] Abnormal power source for Ne speed sensor (At left bank only): Excessively low voltage detected 954
Failure code [CB238] Abnormal power source for Ne speed sensor (At right bank only): Excessively low voltage detected 956
Failure code [CA263] Fuel temperature sensor too high (Left bank): Excessively high voltage detected 958
Failure code [CB263] Fuel temperature sensor too high (Right bank): Excessively high voltage detected 960
Failure code [CA265] Fuel temperature sensor abnormally low level (Left bank): Low voltage detection 962
Failure code [CB265] Fuel temperature sensor abnormally low level (Right bank): Low voltage detection 962
Failure code [CA271] PCV1 short circuit (Left bank): Short circuit 963
Failure code [CB271] PCV1 short circuit (Right bank): Short circuit 964
Failure code [CA272] PCV1 disconnection (Left bank): Disconnection 965
Failure code [CB272] PCV1 disconnection (Right bank): Disconnection1 966
Failure code [CA273] PCV2 short circuit (Left bank): Short circuit 967
Failure code [CB273] PCV2 short circuit (Right bank): Short circuit 968
Failure code [CA274] PCV2 disconnection (Left bank): Disconnection 969
Failure code [CB274] PCV2 disconnection (Right bank): Disconnection1 970
Troubleshooting by failure code, Part 4 973
Failure code [CA322] Injector No 1 (L/B No1) system disconnection or short circuit (Left bank): Disconnection, short circuit 976
Failure code [CA323] Injector No 5 (L/B No5) system disconnection or short circuit (Left bank): Disconnection, short circuit 978
Failure code [CA324] Injector No 3 (L/B No3) system disconnection or short circuit (Left bank): Disconnection, short circuit 980
Failure code [CA325] Injector No 6 (L/B No6) system disconnection or short circuit (Left bank): Disconnection, short circuit 982
Failure code [CA331] Injector No 2 (L/B No2) system disconnection or short circuit (Left bank): Disconnection, short circuit 984
Failure code [CA332] Injector No 4 (L/B No4) system disconnection or short circuit (Left bank): Disconnection, short circuit 986
Failure code [CA342] Engine controller data mismatch (Left bank): Mismatch 988
Failure code [CB342] Engine controller data mismatch (Right bank): Mismatch 988
Failure code [CA351] Abnormal injector drive circuit (Left bank): Abnormal circuit 990
Failure code [CB351] Injector drive circuit abnormality (Right bank): Circuit abnormality 992
Failure code [CA352] Sensor power supply (1) abnormally low level (Left bank): Low voltage detection 994
Failure code [CB352] Sensor power supply (1) abnormally low level (Right bank): Low voltage detection 994
Failure code [CA386] Sensor power supply (1) abnormally high level (Left bank): High voltage detection 996
Failure code [CB386] Sensor power supply (1) abnormally high level (Right bank): High voltage detection 998
Failure code [CA431] Trouble in idle validation switch1000
Failure code [CA432] Idle validation action error1004
Failure code [CA441] Power supply voltage abnormally low level (Left bank): Low voltage detection1005
Failure code [CB441] Power supply voltage abnormally low level (Right bank): Low voltage detection1005
Failure code [CA442] Power supply voltage abnormally high level (Left bank): High voltage detection1006
Failure code [CB442] Power supply voltage abnormally high level (Right bank): High voltage detection1006
Failure code [CA449] Common rail abnormally high pressure (2) (Left bank): Abnormally high pressure occurrence1007
Failure code [CB449] Common rail abnormally high pressure (2) (Right bank): Abnormally high pressure occurrence1007
Failure code [CA451] Common rail pressure sensor too high (Left bank): Excessively high voltage detected1008
Failure code [CB451] Common rail pressure sensor abnormally high level (Right bank): High voltage detection1010
Failure code [CA452] Common rail pressure sensor abnormally low level (Left bank): Abnormally low voltage detection1012
Failure code [CB452] Common rail pressure sensor abnormally low level (Right bank): Abnormally low voltage detection1012
Failure code [CA553] Common rail pressure too high (1) (Left bank): Excessively high pressure detected1013
Failure code [CB553] Common rail pressure too high (1) (Right bank): Excessively high pressure detected1014
Failure code [CA554] In-range error in common rail pressure sensor (Left bank): In-range error1015
Failure code [CA559] Loss of pressure feed from supply pump (1) (Left bank): Loss of pressure feed detected1016
Failure code [CB554] In-range error in common rail pressure sensor (Right bank): In-range error1015
Failure code [CA559] Loss of pressure feed from supply pump (1) (Left bank): Loss of pressure feed detected1016
Failure code [CB559] Loss of pressure feed from supply pump (1) (Right bank): Loss of pressure feed detected1020
Failure code [CA689] Abnormal engine Ne speed sensor (Left bank): Abnormal signal1024
Failure code [CB689] Abnormal engine Ne speed sensor (Right bank): Abnormal signal1026
Failure code [CA691] Intake air temperature sensor abnormally high level (At left bank only): High voltage detection1028
Failure code [CA692] Intake air temperature sensor abnormally low level (At left bank only): Low voltage detection1030
Failure code [CA731] Abnormal engine Bkup speed sensor phase (Left bank): Abnormal phase1031
Failure code [CB731] Abnormal engine Bkup speed sensor phase (Right bank): Abnormal phase1031
Troubleshooting by failure code, Part 51033
Failure code [CA757] Loss of all engine controller data (Left bank): Loss of all data1035
Failure code [CB757] Loss of all engine controller data (Right bank): Loss of all data1035
Failure code [CA778] Abnormal engine Bkup speed sensor (Left bank): Abnormal Bkup signal1036
Failure code [CB778] Engine Bkup speed sensor abnormality (Right bank): Bkup signal error1038
Failure code [CA781] Inter-multicontroller communication error (Left bank): Communication error1040
Failure code [CB781] Inter-multicontroller communication error (Right bank): Communication error1042
Failure code [CA1257] Multicontroller distinction wiring harness key error (Left bank): Distinction error1043
Failure code [CB1257] Multicontroller distinction wiring harness keyerror (Right bank): Distinction error1044
Failure code [CB1548] Injector #7 (R/B #1) system disconnection/shortcircuit (Right bank): Disconnection/Short circuit1046
Failure code [CB1549] Injector #8 (R/B #2) system disconnection/short circuit (Right bank): Disconnection/Short circuit1048
Failure code [CB1551] Injector #10 (R/B #4) system disconnection/short circuit (Right bank): Disconnection/Short circuit1050
Failure code [CB1552] Injector #11 (R/B #5) system disconnection/short circuit (Right bank): Disconnection/Short circuit1052
Failure code [CB1553] Injector #12 (R/B #6) system disconnection/short circuit (Right bank): Disconnection/Short circuit1054
Failure code [CB1622] Injector #9 (R/B #3) system disconnection/short circuit (Right bank): Disconnection/Short circuit1056
Failure code [CA1633] KOMNET abnormality (Left bank): Communication error1058
Failure code [CA2185] Throttle sensor supply voltage high error1060
Failure code [CA2186] Throttle sensor power supply low error1062
Failure code [CA2249] Loss of pressure feed from supply pump (2) (Left bank): Loss of pressure feed detected1063
Failure code [CB2249] Loss of pressure feed from supply pump (2) (Right bank): Loss of pressure feed detected1063
Failure code [CA2555] Intake heater relay voltage low error (Left bank)1064
Failure code [CA2556] Intake heater relay voltage high error (Left bank)11066
Troubleshooting by failure code, Part 61069
Failure code [D180KA] Preheating relay output system: Disconnection1072
Failure code [D180KB] Preheating relay output system: Grounding fault1073
Failure code [D180KY] Preheating relay output system: Hot short circuit1074
Failure code [D19HKB] Stop lamp relay output system: Short circuit1076
Failure code [D1EFKA] Pre-lubrication start relay output system: Disconnection1078
Failure code [D1EFKB] Pre-lubrication start relay output system: Grounding fault1080
Failure code [D1EFKY] Pre-lubrication start relay output system: Hot short circuit1082
Failure code [D1EHKA] Engine start relay output system: Disconnection1084
Failure code [D1EHKB] Engine start relay output system: Grounding fault1086
Failure code [D1EHKY] Engine start relay output system: Hot short circuit1088
Failure code [D1EMKA] Disconnection of Parking Interlock Relay Output Circuit1090
Failure code [D1EMKB] Ground Fault of Parking Interlock Relay Output Circuit1091
Failure code [D1EMKY] Hot Short of Parking Interlock Relay Output Circuit1092
Failure code [D1ENKZ] Failure of Power Ladder Power Supply Relay Output System1093
Failure code [D1EPKA] Disconnection of Power Ladder Pump Drive Relay Output Circuit1094
Failure code [D1EPKB] Ground Fault of Power Ladder Pump Drive Relay Output Circuit1095
Failure code [D1EPKY] Hot Short of Power Ladder Pump Drive Relay Output Circuit1096
Failure code [D1EQKA] Disconnection of Power Ladder Buzzer Relay Output Circuit1097
Failure code [D1EQKB] Ground Fault of Power Ladder Buzzer Relay Output Circuit1098
Failure code [D1EQKY] Hot Short of Power Ladder Buzzer Relay Output Circuit1099
Failure code [D1ERKA] Open Circuit in Power Ladder Raise Solenoid Relay Output Circuit1100
Failure code [D1ERKB] Ground Fault of Power Ladder Raise Solenoid Relay Output Circuit1101
Failure code [D1ERKY] Hot Short in Power Ladder Raise Solenoid Relay Output Circuit1102
Failure code [D1ESKA] Open Circuit in Power Ladder Lower Solenoid Relay Output Circuit1103
Failure code [D1ESKB] Ground Fault of Power Ladder Lower Solenoid Relay Output Circuit1104
Failure code [D1ESKY] Hot Short in Power Ladder Lower Solenoid Relay Output Circuit1105
Failure code [DAF9KM] Wrong connection of connector1106
Failure code [DAFRKR] Abnormal CAN communication (machine monitor): Abnormal communication1107
Failure code [DAQ0KK] Transmission controller direct power supply: Lowering of power supply voltage1108
Failure code [DAQ0KT] Transmission controller nonvolatile memory: Abnormality in controller1110
Failure code [DAQ2KK] Transmission controller solenoid power supply: Power supply voltage too low1112
Failure code [DAQ9KQ] Transmission controller: Disagreement of model selection1114
Failure code [DAQRKR] Abnormality in CAN communication (Transmission)1115
Failure code [DAQRMA] Transmission controller option setting: Malfunction1120
Failure code [DAQV00] Neutral coast prevention control actuation caution: Caution actuated1121
Failure code [DAQW00] Neutral coast state caution: Caution actuated1122
Failure code [DB10KT] Retarder controller nonvolatile memory: Abnormality in controller1123
Failure code [DB12KK] Retarder controller solenoid power supply: Power supply system trouble1124
Failure code [DB13KK] Retarder controller battery direct power supply: Power supply voltage too low1126
Failure code [DB19KQ] Disagreement of model selection (Retarder controller)1128
Failure code [DB1RKR] CAN communication (retarder controller): Communication disabled1130
Failure code [DB1RMA] Disagreement of option setting (Retarder controller)1134
Failure code [DB2RKR] CAN communication (engine controller): Communication disabled1135
Failure code [dB2RKR] CAN communication (engine controller): Communication disabled1143
Failure code [DBB0KK] or VHMS_LED display: “n9” → “01”1150
Failure code [DBB0KQ] (or VHMS_LED display: “nF” → “11”) VHMS controller: Disagreement of model selection signals1152
Failure code [DBB3KK] (or VHMS_LED display: “n9” → “05”) VHMS controller battery power supply: Low power supply voltage (input)1154
Failure code [DBB5KP] (or VHMS_LED display: “n9” → “04”) VHMS controller 5 V power supply output: Low output voltage1156
Failure code [DBB6KP] (or VHMS_LED display: “n9” → “02”) VHMS controller 24 V power supply output: Low output voltage1158
Failure code [DBB7KP] (or VHMS_LED display: “n9” → “03”) VHMS controller 12 V power supply output: Low output voltage1160
Failure code [DBBQKR] (or VHMS_LED display: “n8” → “02”) VHMS controller CAN communication: Defective communication (Abnormality in target component system)1161
Failure code [DBBRKR] Abnormality in CAN communication (VHMS)1161
Failure code [DBC0KT] Abnormality of Non-volatile Memory1162
Failure code [DBC2KK] ABS controller solenoid power supply: Power supply system trouble1164
Failure code [DBC2KK] Solenoid Power Supply: Low Voltage1166
Failure code [DBC3KK] ABS controller battery direct power supply: Power supply voltage too low1168
Failure code [DBC3KK] Direct Battery Power Supply: Low Voltage1170
Failure code [DBC9KQ] Disagreement of model selection (ABS controller)1172
Failure code [DBCRKR] Abnormality in CAN communication (ABS)1173
Failure code [DBCRMA] Disagreement of option setting (ABS controller)1177
Failure code [DBG2KK] Solenoid power supply: Low voltage1178
Failure code [DBG3KK] Battery direct power supply: Low voltage1180
Failure code [DBG9KQ] Model selection signal: Abnormal1182
Failure code [DDD7KX] Trouble in travel speed setting switch system: Out of input signal range1184
Failure code [DDD8KA] ARSC system switch system: Disconnection (If equipped)1186
Failure code [DDD8KB] ARSC system switch system: Short circuit (If equipped)1188
Failure code [DDD9KA] ABS system switch system: Disconnection1190
Failure code [DDD9KB] ABS system switch system: Short circuit1192
Failure code [DDDAKA] ASR system switch: Disconnection1194
Failure code [DDDAKB] ASR system switch: Short circuit1196
Failure code [DDDGL4] Failure of ladder manual operation switch CH1 (inside cab) system1198
Failure code [DDDHL4] Failure of ladder manual operation switch CH2 (outside cab) system1200
Failure code [DDE2KB] Engine oil pressure switch error: Grounding fault1202
Failure code [DDE2L6] Engine oil pressure switch error: Disconnection or hot short circuit1204
Failure code [DDP6L4] Service brake pressure switch trouble (Rear)1206
Failure code [DDTHKA] Hi clutch fill switch: Disconnection1208
Failure code [DDTJKA] Lo clutch fill switch: Disconnection1210
Failure code [DDTKKA] 1st clutch fill switch: Disconnection1212
Failure code [DDTLKA] 2nd clutch fill switch: Disconnection1214
Failure code [DDTMKA] 3rd clutch fill switch: Disconnection1216
Failure code [DDTNKA] R clutch fill switch: Disconnection1218
Failure code [DDTPKA] 4th clutch fill switch: Disconnection1220
Failure code [DDU1KA] Open Circuit in Parking Brake Operation Input Circuit1222
Failure code [DF10KA] Gear shift lever: Disconnection1223
Failure code [DF10KB] Gear shift lever: Short circuit1226
Failure code [DGE5KX] or VHMS_LED display: “n4” → “01”1230
Failure code [DGF1KX] Transmission oil temperature sensor: Out of input signal range1232
Failure code [DGR2KB] Trouble in retarder oil temperature sensor (rear wheel) system (Disconnection and short circuit)1234
Failure code [DGR2KZ] Trouble in retarder oil temperature sensor (rear wheel) system (Ground fault)1236
Failure code [DGR4KB] Trouble in retarder oil temperature sensor (front wheel) system (Disconnection and short circuit)1237
Failure code [DGR4KZ] Trouble in retarder oil temperature sensor (front wheel) system (Ground fault)1238
Failure code [DGR6KX] Steering oil temperature sensor: Input signal out of range1240
Failure code [DGT1KX] Torque converter oil temperature sensor: Out of input signal range1242
Troubleshooting by failure code, Part 71245
Failure code [DGT5KA] (or VHMS_LED display: “n3” → “12”) Left bank exhaust temperature sensor system (Front): Disconnection1247
Failure code [dGT5KA] (or VHMS_LED display: “n3” → “22”) Left bank exhaust temperature sensor system (Rear): Disconnection1250
Failure code [DGT5KB] (or VHMS_LED display: “n3” → “11”) Left bank exhaust temperature sensor system (Front): Short circuit1253
Failure code [dGT5KB] (or VHMS_LED display: “n3” → “21”) Left bank exhaust temperature sensor system (Rear): Short circuit1256
Failure code [DGT6KA] (or VHMS_LED display: “n3” → “24”) Right bank exhaust temperature sensor system (Front): Disconnection1259
Failure code [dGT6KA] (or VHMS_LED display: “n3” → “26”) Right bank exhaust temperature sensor system (Rear): Disconnection1262
Failure code [DGT6KB] (or VHMS_LED display: “n3” → “23”) Right bank exhaust temperature sensor system (Front): Short circuit1265
Failure code [dGT6KB] (or VHMS_LED display: “n3” → “25”) Right bank exhaust temperature sensor system (Rear): Short circuit1268
Failure code [DHE5KB] or VHMS_LED display: “n3” → “32” Blow-by pressure sensor: Short circuit1271
Failure code [DHE5KY] or VHMS_LED display: “n3” → “31” Blow-by pressure sensor: Short circuit with power supply line1274
Failure code [DHP4KY] or VHMS_LED display: “n5” → “44” Short circuit in suspension pressure sensor system (Front right)1276
Failure code [DHP4KZ] or VHMS_LED display: “n5” → “43” Disconnection or ground fault in suspension pressure sensor system(Front right)1278
Failure code [DHP5KY] or VHMS_LED display: “n5” → “54” Short circuit in suspension pressure sensor system (Front left)1280
Failure code [DHP5KZ] or VHMS_LED display: “n5” → “53” Disconnection or ground fault in suspension pressure sensor system(Front left)1282
Failure code [DHP6KA] Suspension pressure sensor system: Disconnection (Right rear)1284
Failure code [DHP6KX] Failure in suspension pressure sensor system trouble: Out of input signal range (Right rear)1285
Failure code [DHP6KY] or VHMS_LED display: “n5” → “64” Suspension pressure sensor system: Short circuit (Right rear)1288
Failure code [DHP6KZ] or VHMS_LED display: “n5” → “63” Suspension pressure sensor system: Disconnection or ground fault (Right rear)1290
Failure code [DHP7KA] Suspension pressure sensor system: Disconnection (Left rear)1292
Failure code [DHP7KX] Failure in suspension pressure sensor system trouble: Out of input signal range (Left rear)1293
Failure code [DHP7KY] or VHMS_LED display: “n5” → “74” Suspension pressure sensor system: Short circuit (Left rear)1296
Failure code [DHP7KZ] or VHMS_LED display: “n5” → “73” Suspension pressure sensor system: Disconnection or ground fault (Left rear)1298
Failure code [DHT5KX] Torque converter oil pressure sensor: Out of input signal range1300
Failure code [DHT5L6] Torque converter oil pressure sensor: Disagreement of run and stop condition with signal1302
Failure code [DHU2KX] Front accumulator oil pressure sensor: Out of input signal range1304
Failure code [DHU3KX] Rear accumulator oil pressure sensor: Out of input signal range1306
Failure code [DHU6KX] Trouble in ABS control valve pressure sensor (Front right)1308
Failure code [DHU7KX] Trouble in ABS control valve pressure sensor (Front left)1310
Failure code [DHU8KX] Trouble in ABS control valve pressure sensor (Front right)1312
Failure code [DHU9KX] Trouble in ABS control valve pressure sensor (Front right)1314
Failure code [DHUTKX] Trouble in ABS cut valve pressure sensor1316
Failure code [DJF1KA] Fuel level sensor: Disconnection1318
Failure code [DK30KX] Steering angle potentiometer: Trouble (Disconnection)1320
Failure code [DK51L5] Retarder lever potentiometer: Potentiometer signal is inconsistent with swich signal1321
Failure code [DK52KX] Failure in hoist lever potentiometer 1: Out of input signal range1324
Failure code [DK53L8] Failure in hoist lever potentiometer 2: Disagreement of analog signal1326
Failure code [DK54KX] Body positioner sensor: Out of input signal range1328
Failure code [DK5VKX] Abnormality of Power Ladder Position Input Signal (Out of Range)1330
Failure code [DK5VMA] Power Ladder System Abnormality1332
Failure code [DK60KX] Trouble in acceleration sensor (out of range)1334
Failure code [DKD0L6] Failure in steering speed sensor1336
Failure code [DKH0KX] Clinometer sensor signal out of range1338
Failure code [DKH1KX] (or VHMS_LED display: “n4” → “33”) Abnormality in clinometer sensor1340
Failure code [DLF1KA] Transmission input shaft speed sensor: Disconnection1342
Failure code [DLF1LC] Transmission input shaft speed sensor: Disagreement of revolution speed signal1344
Failure code [DLF2KA] Transmission intermediate shaft speed sensor: Disconnection1346
Failure code [DLF2LC] Transmission intermediate shaft speed sensor: Disagreement of revolution speed signal1348
Troubleshooting by failure code, Part 81351
Failure code [DLF6KA] Disconnection in wheel speed sensor (Front right)1354
Failure code [DLF6L3] Trouble in wheel speed sensor (Front right)1356
Failure code [DLF7KA] Disconnection in wheel speed sensor (Front left)1358
Failure code [DLF7L3] Trouble in wheel speed sensor (Front left)1360
Failure code [DLF8KA] Wheel speed sensor: Disconnection (Rear right)1362
Failure code [DLF8L3] Wheel speed sensor: Disconnection (Rear right)1364
Failure code [DLF8LC] Wheel speed sensor: Trouble (Rear right)1366
Failure code [DLF8MA] Wheel speed sensor: Disconnection (Rear right)1366
Failure code [DLF9KA] Wheel speed sensor: Disconnection (Rear left)1368
Failure code [DLF9L3] Wheel speed sensor: Trouble (Rear left)1370
Failure code [DLF9LC] Wheel speed sensor: Trouble (Rear left)1372
Failure code [DLF9MA] Wheel speed sensor: Disconnection (Rear left)1372
Failure code [DLT3KA] Transmission output shaft speed sensor: Disconnection1374
Failure code [DLT3LC] Transmission output shaft speed sensor: Disagreement of revolution speed signal1376
Failure code [DLT4KA] Transmission output shaft speed sensor: Disconnection1378
Failure code [DLT4MA] Transmission output shaft speed sensor: Disconnection1380
Failure code [DUM7KY] Pre-lubrication operation lamp output abnormality: Hot short circuit1382
Failure code [DUM7KZ] Pre-lubrication operation lamp output abnormality: Disconnection or grounding fault1384
Failure code [DUM9KZ] Failure of power ladder indicator system1386
Failure code [DV00KB] Buzzer output: Short circuit1388
Failure code [DW2AKA] Main pressure variable valve output: Disconnection1390
Failure code [DW2AKB] Main pressure variable valve output circuit: Ground fault1392
Failure code [DW2AKY] Main pressure variable valve output circuit: Hot short1394
Failure code [DW2AL1] Main pressure variable valve: Defective reset1396
Failure code [DW2ALH] Main pressure variable valve: Malfunction1398
Failure code [DW2BKA] Main oil level selector valve output: Disconnection1399
Failure code [DW2BKB] Main oil level selector valve output circuit: Ground fault1400
Failure code [DW2BKY] Main oil level selector valve output circuit: Hot short1402
Failure code [DW2BL1] Main oil level selector valve: Defective reset1404
Failure code [DW2BLH] Main oil level selector valve: Malfunction1406
Failure code [DW2CKA] Transmission lubrication variable valve output: Disconnection1407
Failure code [DW2CKB] Transmission lubrication variable valve output circuit: Ground fault1408
Failure code [DW2CKY] Transmission lubrication variable valve output circuit: Hot short1410
Failure code [DW2CL1] Transmission lubrication variable valve: Defective reset1412
Failure code [DW2CLH] Transmission lubrication variable valve: Malfunction1414
Failure code [DW35KZ] Failure in output system of auto suspension solenoid 1: Disconnection or short circuit1416
Failure code [DW36KZ] Failure in output system of auto suspension solenoid 2: Disconnection or short circuit1418
Failure code [DW71KZ] Exhaust brake output system trouble (Disconection/Ground fault/Hot short)1420
Failure code [DW72KZ] Kick-out solenoid output system trouble: Disconnection or short circuit1422
Failure code [DW73KZ] Failure in hoist select valve output system: Disconnection or short circuit1424
Failure code [DW78KZ] Brake cooling valve (BCV) (rear wheel) output system trouble: Disconnection or short circuit1426
Failure code [DWNBK4] ASR shut-off valve: Trouble (Valve keeps operating)1428
Failure code [DWNBKA] ASR shut-off valve output circuit: Disconnection1430
Failure code [DWNBKB] ASR shut-off valve output circuit: Ground fault1432
Failure code [DWNBKY] ASR shut-off valve output circuit: Short circuit1434
Failure code [DWNBMA] ASR shut-off valve: Trouble (Valve does not operate)1435
Failure code [DWNDKZ] Trouble in ABS cut-off valve (Front) system1436
Failure code [DWNDMA] Defective ABS cut-off valve (Front)1438
Failure code [DWNEKZ] Trouble in ABS cut-off valve (Rear) system1440
Failure code [DWNEMA] Defective ABS cut-off valve (Rear)1442
Failure code [DWNLKA] Open Circuit in Power Ladder Shock Reducing Solenoid Output Circuit1444
Failure code [DWNLKB] Ground Fault of Power Ladder Shock Reducing Solenoid Output Circuit1445
Failure code [DWNLKY] Hot Short in Power Ladder Shock Reducing Solenoid Output Circuit1446
Troubleshooting by failure code, Part 91449
Failure code [DX11K4] Rear brake proportional pressure reducing solenoid valve: Out of control1452
Failure code [DX11KA] Rear brake proportional pressure reducing solenoid valve output circuit: Disconnection1454
Failure code [DX11KB] Rear brake proportional pressure reducing solenoid valve: Short circuit1455
Failure code [DX11KY] Rear brake proportional pressure reducing solenoid valve: Short circuit to power source line1456
Failure code [DX11MA] Rear brake proportional pressure reducing solenoid valve: Malfunction1457
Failure code [DX12K4] Front brake proportional pressure reducing solenoid valve: Out of control1458
Failure code [DX12KA] Front brake proportional pressure reducing solenoid valve output circuit: Disconnection1460
Failure code [DX12KB] Front brake proportional pressure reducing solenoid valve: Short circuit1461
Failure code [DX12KY] Front brake proportional pressure reducing solenoid valve: Short circuit to power source line1462
Failure code [DX12MA] Front brake proportional pressure reducing solenoid valve: Malfunction1463
Failure code [DX13KA] Output circuit of hoist EPC valve: Disconnection1464
Failure code [DX13KB] Output circuit of hoist EPC valve: Short circuit1466
Failure code [DX13KY] Output circuit of hoist EPC valve: Short circuit with power source line1468
Failure code [DX17K4] ASR proportional pressure reducing solenoid valve (right): Trouble (Valve keeps operating)1470
Failure code [DX17KA] ASR proportional pressure reducing solenoid valve (right) output circuit: Disconnection1472
Failure code [DX17KB] ASR proportional pressure reducing solenoid valve (right) output circuit: Ground fault1474
Failure code [DX17KY] ASR proportional pressure reducing solenoid valve (right) output circuit: Short circuit1476
Failure code [DX17MA] ASR proportional pressure reducing solenoid valve (right): Trouble (Valve does not operate)1477
Failure code [DX18K4] ASR proportional pressure reducing solenoid valve (left): Trouble (Valve keeps operating)1478
Failure code [DX18KA] ASR proportional pressure reducing solenoid valve (left) output circuit: Disconnection1480
Failure code [DX18KB] ASR proportional pressure reducing solenoid valve (left) output circuit: Ground fault1482
Failure code [DX18KY] ASR proportional pressure reducing solenoid valve (left) output circuit: Short circuit1484
Failure code [DX18MA] ASR proportional pressure reducing solenoid valve (left): Trouble (Valve does not operate)1485
Failure code [DX21KA] Disconnection in ABS control valve output circuit (Front right)1486
Failure code [DX21KB] Ground fault in ABS control valve output circuit (Front right)1487
Failure code [DX21KY] Hot short in ABS control valve output circuit (Front right)1488
Failure code [DX21MA] Defective ABS control valve (Front right)1489
Failure code [DX22KA] Disconnection in ABS control valve output circuit (Front left)1490
Failure code [DX22KB] Ground fault in ABS control valve output circuit (Front left)1491
Failure code [DX22KY] Hot short in ABS control valve output circuit (Front left)1492
Failure code [DX22MA] Defective ABS control valve (Front left)1493
Failure code [DX23KA] Disconnection in ABS control valve output circuit (Rear right)1494
Failure code [DX23KB] Ground fault in ABS control valve output circuit (Rear right)1495
Failure code [DX23KY] Hot short in ABS control valve output circuit (Rear right)1496
Failure code [DX23MA] Defective ABS control valve (Rear right)1497
Failure code [DX24KA] Disconnection in ABS control valve output circuit (Rear left)1498
Failure code [DX24KB] Ground fault in ABS control valve output circuit (Rear left)1499
Failure code [DX24KY] Hot short in ABS control valve output circuit (Rear left)1500
Failure code [DX24MA] Defective ABS control valve (Rear left)1501
Failure code [DX25MA] Defective ABS front wheel system control valve1502
Failure code [DX26MA] Defective ABS rear wheel system control valve1502
Troubleshooting by failure code, Part 101505
Failure code [DXH1KA] Lockup clutch solenoid output circuit: Disconnection1508
Failure code [DXH1KB] Lockup clutch solenoid output circuit: Short circuit1510
Failure code [DXH1KY] Lockup clutch solenoid output circuit: Short circuit to power supply line1512
Failure code [DXH2KA] Hi clutch solenoid output circuit: Disconnection1514
Failure code [DXH2KB] Hi clutch solenoid output circuit: Short circuit1516
Failure code [DXH2KY] Hi clutch solenoid output circuit: Short circuit to power supply line1518
Failure code [DXH3KA] Lo clutch solenoid output circuit: Disconnection1522
Failure code [DXH3KB] Lo clutch solenoid output circuit: Short circuit1524
Failure code [DXH3KY] Lo clutch solenoid output circuit: Short circuit in power supply line1526
Failure code [DXH4KA] 1st clutch solenoid output circuit: Disconnection1530
Failure code [DXH4KB] 1st clutch solenoid output circuit: Short circuit1532
Failure code [DXH4KY] 1st clutch solenoid output circuit: Short circuit to power supply line1534
Failure code [DXH5KA] 2nd clutch solenoid output circuit: Disconnection1538
Failure code [DXH5KB] 2nd clutch solenoid output circuit: Short circuit1540
Failure code [DXH5KY] 2nd clutch solenoid output circuit: Short circuit in power supply line1542
Failure code [DXH6KA] 3rd clutch solenoid output circuit: Disconnection1546
Failure code [DXH6KB] 3rd clutch solenoid output circuit: Short circuit1548
Failure code [DXH6KY] 3rd clutch solenoid output circuit: Short circuit to power supply line1550
Failure code [DXH7KA] R clutch solenoid output circuit: Disconnection1554
Failure code [DXH7KB] R clutch solenoid output circuit: Short circuit1556
Failure code [DXH7KY] R clutch solenoid output circuit: Short circuit to power supply line1558
Failure code [DXHHKA] 4th clutch solenoid output circuit: Disconnection1560
Failure code [DXHHKB] 4th clutch solenoid output circuit: Short circuit1562
Failure code [DXHHKY] 4th clutch solenoid output circuit: Short circuit to power supply line1564
Failure code [F@BBZL] or VHMS_LED display: “n3” → “38” Blow-by pressure: High error1567
Failure code [F@BYNS] (or VHMS_LED display “n3” → “61”) Left front exhaust temperature sensor (1): Exhaust temperature abnormal rise1568
Failure code [f@BYNS] (or VHMS_LED display “n3” → “71”) Left rear exhaust temperature sensor (1): Exhaust temperature abnormal rise1570
Failure code [F@BZNS] (or VHMS_LED display “n3” → “81”) Right front exhaust temperature sensor (1): Exhaust temperature abnormal rise1572
Failure code [f@BZNS] (or VHMS_LED display “n3” → “91”) Right rear exhaust temperature sensor (1): Exhaust temperature abnormal rise1574
Failure code [F@BYNR] (or VHMS_LED display “n3” → “62”) Left front exhaust temperature sensor (2): Exhaust temperature abnormal rise1576
Failure code [f@BYNR] (or VHMS_LED display “n3” → “72”) Left rear exhaust temperature sensor (2): Exhaust temperature abnormal rise1578
Failure code [F@BZNR] (or VHMS_LED display “n3” → “82”) Right front exhaust temperature sensor (2): Exhaust temperature abnormal rise1580
Failure code [f@BZNR] (or VHMS_LED display “n3” → “92”) Right rear exhaust temperature sensor (2): Exhaust temperature abnormal rise1582
Troubleshooting of electrical system (E-mode)1585
Before troubleshooting of electric system1587
Contents of troubleshooting table1588
E-1 Engine does not start1589
E-2 Automatic preheating does not operate1592
E-3 Machine monitor does not display all, when starting switch is turned ON1596
E-4 Machine monitor does not operate when starting switch is OFF1598
E-5 Alarm buzzer does not sound1600
E-6 Alarm buzzer does not stop sounding1602
E-7 Gauges of machine monitor, caution lamps or character display section do not display properly1603
E-8 A selection of the display in character display section cannot be changed1605
E-9 Power mode selecting function does not operate properly1608
E-10 AISS function does not operate properly1609
E-11 Seat belt caution lamp does not display properly1610
E-12 Turn signal lamp or turning lamp (hazard lamp) do not work properly1611
E-13 Night illumination (lighting) does not work properly1614
E-14 Emergency steering does not operate1626
E-15 Hoist lever does not operate normally1636
E-16 Power supply system (Air conditioner does not operate)1638
E-17 Compressor and refrigerant system (Air is not cooled)1640
E-18 Blower motor system (Air does not come out or air flow is abnormal)1642
E-19 Ladder cannot be lowered with operation switch outside cab1644
E-20 Ladder cannot be lowered with operation switch inside cab1645
E-21 Ladder continues lowering1646
E-22 Ladder cannot be raised with operation switch outside cab1647
E-23 Ladder cannot be lowered with operation switch inside cab1648
E-24 Ladder continues rising1649
E-25 Buzzer does not sound when power ladder is operated1650
E-26 Power ladder pump does not operate1651
E-27 Cannot access to the setting screen of the mobile communication terminal (machine without KOMTRAX Plus controller)1652
E-28 Cannot log in to the setting screen of the mobile communication terminal because the log in password is unknown (machine without KOMTRAX Plus controller)1657
E-29 VHMS controller is not detected (machine without KOMTRAX Plus controller)1659
E-30 VHMS controller does not become active (machine without KOMTRAX Plus controller)1660
E-31 Communication between mobile communication terminal and KOMTRAX Plus server fails (machine without KOMTRAX Plus controller)1661
E-32 Data is not sent to KOMTRAX Plus server (machine without KOMTRAX Plus controller)1664
E-33 Cannot access to the setting screen of the mobile communication terminal (machine with KOMTRAX Plus controller)1666
E-34 Cannot log in to the setting screen of the mobile communication terminal because the log in password is unknown (machine with KOMTRAX Plus controller)1671
E-35 KOMTRAX Plus controller is not detected (machine with KOMTRAX Plus controller)1673
E-36 KOMTRAX Plus controller does not become active (machine with KOMTRAX Plus controller)1674
E-37 Communication between mobile communication terminal and KOMTRAX Plus server fails (machine with KOMTRAX Plus controller)1675
E-38 Data is not sent to KOMTRAX Plus server (machine with KOMTRAX Plus controller)1678
Troubleshooting of hydraulic and mechanical system (H-mode)1681
Contents of troubleshooting table1683
H-1 Machine does not start1684
H-2 Machine does not travel smoothly (hunting)1686
H-3 Lockup cannot be cancelled1686
H-4 Excessive shock when starting or shifting excessive1687
H-5 Transmission does not shift up1688
H-6 Machine lacks power or speed when traveling1690
H-7 Time lag is excessive when starting or shifting gear1694
H-8 Torque converter oil temperature is high1696
H-9 Torque converter oil pressure is low1697
H-10 Front brake is ineffective1698
H-11 Rear brake is ineffective1699
H-12 Steering wheel is heavy1700
H-13 Steering wheel does not work1701
H-14 Steering wheel vibrates1702
H-15 Dump body lifting speed is slow1703
H-16 Dump body does not work1704
H-17 Excessive hydraulic drift of dump body1705
H-18 Power ladder does not move or its speed is low1706
Troubleshooting of engine (S-mode)1709
Method of using troubleshooting charts1711
S-1 Starting performance is poor11714
S-2 Engine does not start1715
S-3 Engine does not pick up smoothly1718
S-4 Engine stops during operations1719
S-5 Engine does not rotate smoothly1720
S-6 Engine lacks output (or lacks power)1721
S-7 Exhaust smoke is black (incomplete combustion)1723
S-8 Oil consumption is excessive (or exhaust smoke is blue)1724
S-9 Oil becomes contaminated quickly1725
S-10 Fuel consumption is excessive1726
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)11727
S-12 Oil pressure drops1728
S-13 Oil level rises (Entry of coolant or fuel)1729
S-14 Coolant temperature becomes too high (overheating)1730
S-15 Abnormal noise is made1731
S-16 Vibration is excessive1732
50 Disassembly and assembly1735
General information on disassembly and assembly1735
Precautions before work1736
How to read this manual1737
Coating materials list1739
Special tool list1742
Sketches of special tools1751
Engine and cooling system1787
Removal and installation of fuel supply pump assembly1788
Removal and installation of fuel injector assembly1793
Removal and installation of cylinder head assembly1794
Removal and installation of engine hood assembly1811
Removal and installation of radiator assembly1814
Removal and installation of engine assembly1824
Removal and installation of engine front oil seal1831
Removal and installation of engine rear oil seal1836
Power train, Part 11843
Removal and installation of front drive shaft1844
Removal and installation of rear drive shaft assembly1847
Removal and installation of output shaft assembly1850
Disassembly and assembly of damper assembly1859
Removal and installation of torque converter and transmission assemblies1861
Disconnection and connection of torque converter assembly and transmission assembly1866
Disassembly and assembly of torque converter and PTO assembly1882
Disassembly and assembly of transmission assembly1901
Power train, Part 21947
Removal and installation of final drive carrier assembly1948
Disassembly and assembly of final drive carrier assembly1952
Removal and installation of differential assembly1954
Disassembly and assembly of differential assembly1960
Steering system1983
Removal and installation of steering cylinder assembly1984
Disassembly and assembly of steering cylinder assembly1987
Removal and installation of steering valve assembly1993
Disassembly and assembly of steering valve assembly1996
Brake system2009
Removal and installation of front wheel hub and brake assembly2010
Disassembly and assembly of front wheel hub and brake assembly2016
Removal and installation of final drive and rear brake assembly2025
Disassembly and assembly of final drive and rear brake assembly2029
Undercarriage and frame2073
Removal and installation of front wheel assembly2074
Removal and installation of rear wheel assembly2078
Removal and installation of front suspension cylinder assembly2082
Disassembly and assembly of front suspension cylinder assembly (cylinder with buffer ring)2086
Removal and installation of king pin2093
Removal and installation of rear suspension cylinder assembly2097
Disassembly and assembly of rear suspension cylinder assembly2100
Hydraulic system2111
Removal and installation of hoist valve assembly2112
Disassembly and assembly of hoist valve assembly2115
Disassembly and assembly of hoist cylinder assembly2118
Body2127
Removal and installation of body assembly2128
Cab and its attachments2133
Disassembly and assembly of operator’s seat assembly2134
Removal and installation of air conditioner unit assembly2145
Electrical system, Part 12151
Removal and installation of engine controller assembly2152
Removal and installation of transmission controller assembly2153
Removal and installation of retarder controller assembly2154
Removal and installation of ABS controller assembly2155
Removal and installation of VHMS controller assembly2156
Electrical system, Part 22159
Removal and installation of mobile communication terminal (Machine without KOMTRAX Plus controller)2160
Removal and installation of DC/DC converter (Machine without KOMTRAX Plus controller)2162
Removal and installation of mobile communication terminal harness (Machine without KOMTRAX Plus controller)2164
80 Appendix2175
Air conditioner2175
Precautions before work2177
Precautions for refrigerant2178
Configuration and function of refrigeration cycle2179
Outline of refrigeration cycle2180
Air conditioner unit2182
Air conditioner control panel2188
Troubleshooting procedure2190
Circuit diagram and arrangement of connector pins2192
System diagram2194
Details of air conditioner unit2195
Inspection by self-diagnosis function2196
Testing temperature control system2197
Testing vent (mode) changeover2198
Testing FRESH/RECIRC air changeover2200
Check evaporator temperature sensor2202
Testing relays2203
Troubleshooting chart 12204
Troubleshooting chart 22205
Information in troubleshooting table2207
Troubleshooting for power supply system (Air conditioner does not operate)2208
Troubleshooting for compressor and refrigerant system (Air is not cooled)2211
Troubleshooting for blower motor system (No air comes out or air flow is abnormal)2215
Troubleshooting for temperature control2218
Troubleshooting for vent (mode) changeover2220
Troubleshooting for FRESH/RECIRC air changeover2222
Troubleshooting with gauge pressure2225
Connection of service tool2227
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit2228
Handling of compressor oil2230
90 Diagrams and drawings2233
Hydraulic diagrams and drawings2233
Power train hydraulic circuit diagram2235
Steering and hoist hydraulic circuit diagram2237
Brake hydraulic circuit diagram2241
Brake hydraulic circuit diagram (ASR specification)2243
Brake hydraulic circuit diagram (ABS specification)2245
Brake hydraulic circuit diagram (ASR and ABS specification)2247
Hydraulic circuit diagram for power ladder2249
Electrical diagrams and drawings2251
Electrical circuit diagram for outside cab2253
Electrical circuit diagram for inside cab2271
Electrical circuit diagram for ABS(Outside cab)2301
Electrical circuit diagram for ABS(Inside cab)2303
Electrical circuit diagram for ASR2305
Electrical circuit diagram for power ladder2307
Air conditioner electrical circuit diagram2309
Electrical circuit diagram for auto greasing2311
Electrical circuit diagram of external power supply heater2312
Electrical circuit diagram of KOMTRAX Plus controller (machine with KOMTRAX Plus controller)2313
Electrical circuit diagram of mobile communication terminal (machine with mobile communication terminal)2315

S.M 30/12/24