Komatsu HD 785-7 Dump Truck Shop Manual SEN05900-01-N1-00 – PDF DOWNLOAD 

Description

Komatsu HD 785-7 Dump Truck Shop Manual SEN05900-01-N1-00 – PDF DOWNLOAD

FILE DETAILS:

Komatsu HD 785-7 Dump Truck Shop Manual SEN05900-01-N1-00 – PDF DOWNLOAD

Language : English
Pages : 1927
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu HD 785-7 Dump Truck Shop Manual SEN05900-01-N1-00 – PDF DOWNLOAD 

SERIAL NUMBERS N10561 and up

Front Cover 1
00 Index and foreword 0
Index 4
Composition of shop manual 5
Table of contents 7
Foreword and general information 24
Foreword and general informationSafety notice 25
How to read the shop manual 30
Explanation of terms for maintenance standard 32
Handling of hydraulic components 34
Method of disconnecting and connecting push-pull type coupler 36
Handling of electric equipment 39
How to read electric wire code 49
Precautions when performing work 52
Standard tightening torque table 55
List of Abbreviation 59
Conversion table 63
01 Specification 0
Specification and technical data 70
Specification drawing 71
Specifications 73
Weight table 76
Fuel, coolant and lubricants 77
10 Structure, function andmaintenance standard 0
Engine and cooling system 82
Radiator, brake, torque converter oil cooler, aftercooler, steering, hoist oil cooler 83
Fuel system 85
Power train, Part 1 88
Power train skeleton 89
Output shaft 91
Drive shaft 93
Torque converter and transmission hydraulic piping 95
Brake cooling oil control valve (BCV) 97
Torque converter 99
Torque converter valve 106
Transmission 109
Transmission control valve 137
ECMV 139
Power train, Part 2 150
Axle 151
Differential 153
Final drive 154
Wheels 155
Steering system 158
Steering column 159
Steering linkage 160
Brake system 164
Brake piping 165
Brake valve 167
Secondary brake valve 170
Accumulator charge valve 171
Accumulator 176
Slack adjuster 178
Brake, parking brake 182
Parking brake solenoid 188
Retarder control valve 189
Exhaust brake 190
Undercarriage and frame 194
Suspension 195
Suspension cylinder 197
Rear axle support 205
Hydraulic system 208
Steering and hoist hydraulic piping 209
Steering, hoist filter (high pressure circuit) 211
Dump body control 213
Power ladder system (If equipped) 215
Hydraulic tank 221
Steering valve 222
Crossover relief valve 226
Steering cylinder 227
Steering control valve 228
Hoist valve 237
Dump control valve (EPC valve) 243
Hydraulic pump 245
Work equipment (Body) 250
Auto greasing system (If equipped) 251
Hoist cylinder 262
Cab and its attachments 264
ROPS cab 265
Air conditioner 266
Rear view monitor system 275
Controller related 280
Electrical system, Part 1 282
Machine monitor system 283
Electrical system, Part 2 308
Automatic shift control system 309
External power supply heater 329
Automatic emergency steering system 331
Automatic suspension system 335
Retarder control system 338
Dump control lever 351
Ladder control function (If equipped) 355
Electrical system, Part 3 358
VHMS controller related 359
ABS/ASR system 385
Altitude setting function 403
Speed limit function 406
Electrical system, Part 4 412
Sensors, switches 413
20 Standard value table 0
Standard service value table 432
Standard value table for engine 433
Standard value table for machine 435
30 Testing and adjusting 0
Testing and adjusting, Part 1 448
Testing and adjusting tools list 450
Sketch of special tool 455
Testing engine speed 456
Testing air supply pressure (boost pressure) 457
Testing exhaust temperature 459
Testing exhaust gas color 461
Adjustment of valve clearance 463
Testing compression pressure 465
Testing blow-by pressure 467
Testing engine oil pressure 468
Handling of fuel system devices 469
Releasing residual pressure from fuel system 469
Testing fuel pressure 470
Reduced cylinder mode operation1 471
No-injection cranking 471
Testing leakage-from pressure limiter and return rate from injector 472
Bleeding air from fuel circuit (Standard spec ) 475
Bleeding air from fuel circuit (Extra low-grade fuel spec ) 479
Testing the fuel circuit for leakage1 481
Replacement and adjustment of fan belt 482
Testing and adjusting alternator belt tension 483
Testing and adjusting air conditioner compressor belt 484
Testing and adjusting, Part 2 486
Testing torque converter stall speed 488
Testing power train oil pressure 490
Adjusting transmission speed sensor 498
Testing and adjusting brake oil pressure 499
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas 502
Testing brake performance 507
Bleeding air from brake circuit 509
Bleeding air from ASR circuit (if equipped) 511
Testing wear of front brake disc 512
Testing wear of rear brake disc 513
Method of releasing parking brake in an emergency 514
Testing and adjusting front suspension cylinder 515
Testing and adjusting rear suspension cylinder 519
Testing and adjusting front suspension cylinder (Automatic suspension specification) 523
Testing and adjusting hydraulic pressure in steering, hoist circuit 524
Testing and adjusting oil pressure in dump EPC circuit 527
Air bleeding from steering cylinder 528
Procedure for raising dump body in emergency 529
Adjusting body positioner sensor 530
Handling of high voltage circuit of engine controller 532
Adjusting transmission controller 532
Method for emergency escape at electrical system failure 533
Testing and adjusting ladder potentiometer 537
Calibration method of ladder position 538
Testing and adjusting, Part 3 542
Setting and adjusting of devices 543
Testing and adjusting, Part 4 558
Special functions of machine monitor (EMMS) 559
Testing and adjusting, Part 5 630
Opening ORBCOMM terminal 631
VHMS controller initial setting procedure 633
Precautions for replacing VHMS controller 658
Pm Clinic check sheet 664
Initial setting of payload meter 668
Setting of payload meter built in VHMS 669
40 Troubleshooting 0
Failure code table and fuse locations 678
Failure codes table 679
Fuse locations 695
General information on troubleshooting 702
Points to remember when troubleshooting 703
Sequence of events in troubleshooting 704
Check before troubleshooting 705
Classification and procedures for troubleshooting 706
Contents of troubleshooting table 707
Connector list and layout 709
Connection table for connector pin numbers 728
T- branch box and T- branch adapter table 764
Troubleshooting by failure code, Part 1 768
Failure code [1500L0] Dual engagement 770
Failure code [15B0NX] Transmission oil filter: Clogging 771
Failure code [15F0KM] R -> F shifting abuse 1: Mistake in operation 773
Failure code [15F0MB] R -> F shifting abuse 2: Mistake in operation 773
Failure code [15F7KM] Forward clutch disk abuse: Mistake in operation or setting 774
Failure code [15G0MW] R clutch: Slipping 775
Failure code [15G7KM] Reverse clutch disk abuse: Mistake in operation or setting 777
Failure code [15H0MW] Hi clutch: Slipping 779
Failure code [15J0MW] Lo clutch: Slipping 781
Failure code [15K0MW] 1st clutch: Slipping 783
Failure code [15L0MW] 2nd clutch: Slipping 785
Failure code [15M0MW] 3rd clutch: Slipping 787
Failure code [15N0MW] 4th clutch: Slipping 789
Failure code [15SBL1] R clutch solenoid: Fill signal is ON when command current is OFF 791
Failure code [15SBMA] R clutch solenoid: Malfunction 793
Failure code [15SCL1] Hi clutch solenoid: Fill signal is ON when command current is OFF 795
Failure code [15SCMA] Hi clutch solenoid: Malfunction 798
Failure code [15SDL1] Lo clutch solenoid: Fill signal is ON when command current is OFF 799
Failure code [15SDMA] Lo clutch solenoid: Malfunction 802
Failure code [15SEL1] 1st clutch solenoid: Fill signal is ON when command current is OFF 803
Failure code [15SEMA] 1st clutch solenoid: Malfunction 806
Troubleshooting by failure code, Part 2 808
Failure code [15SFL1] 2nd clutch solenoid: Fill signal is ON when command current is OFF 811
Failure code [15SFMA] 2nd clutch solenoid: Malfunction 814
Failure code [15SGL1] 3rd clutch solenoid: Fill signal is ON when command current is OFF 815
Failure code [15SGMA] 3rd clutch solenoid: Malfunction 818
Failure code [15SHL1] 4th clutch solenoid: Fill signal is ON when command current is OFF 819
Failure code [15SHMA] 4th clutch solenoid: Malfunction 822
Failure code [15SJMA] Lockup clutch solenoid: Malfunction 823
Failure code [2F00KM] Parking brake: Mistake in operation or setting 825
Failure code [2G42ZG] Accumulator: Oil pressure reduction (Front) 828
Failure code [2G43ZG] Accumulator: Oil pressure reduction (Rear) 828
Failure code [989A00] Engine over run prevention command signal: Operating 829
Failure code [989D00] Rear section tipping over alarm: Alarm isactivated 829
Failure code [989X00] Overspeed alarm: Alarm operation 830
Failure code [989Y00] Overload alarm: Speed limit function operation 830
Failure code [989Z00] Parking Brake Interlock Caution 831
Failure code [A570NX] Engine oil filter: Clogging 833
Failure code [AA10NX] Air cleaner element: Clogging 835
Failure code [AB00L4] Alternator: Failure on battery charge circuit (R terminal signal is present and engine is stopped) 837
Failure code [AB00MA] Alternator: Malfunction 839
Failure code [AB00MB] Alternator: Failure on battery charge circuit (Absence of R terminal signal and detection error) 841
Failure code [B@BAZG] Abnormal lowering of engine oil pressure: Lowering of oil pressure 843
Failure code [B@BAZK] Engine oil: Level too low 845
Failure code [B@BCNS] Engine: Overheat 847
Failure code [B@BCZK] Lowering of radiator coolant: Lowering of level 849
Failure code [B@BFZK] Lowering of fuel level 851
Failure code [B@C6NS] Brake cooling oil: Overheating (Front) 852
Failure code [B@C7NS] Brake cooling oil: Overheating (Rear) 853
Failure code [B@CENS] Overheating of torque converter oil 855
Failure code [B@GAZK] Battery electrolyte level: Lowering of level 856
Failure code [B@JANS] Steering oil temperature: Overheat 857
Troubleshooting by failure code, Part 3 860
Failure code [CA111] Engine controller (Left bank): Internal abnormality1 863
Failure code [CB111] Engine controller (Right bank): Internal abnormality 865
Failure code [CA115] Abnormal engine Ne and Bkup speed sensors (Left bank): Abnormal speed sensor signal 867
Failure code [CB115] Abnormal engine Ne and Bkup speed sensors (Right bank): Abnormal speed sensor signal 868
Failure code [CA122] Charge pressure sensor too high (At left bank only): Excessively high voltage detected 869
Failure code [CA123] Charge pressure sensor too low (At left bank only): Excessively low voltage detected 871
Failure code [CA131] Throttle sensor high error (At left bank only) 873
Failure code [CA132] Throttle sensor low error (At left bank only) 875
Failure code [CA135] Oil pressure sensor too high (At left bank only):Excessively high voltage detected 877
Failure code [CA141] Oil pressure sensor too low (At left bank only):Excessively low voltage detected 879
Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected 881
Failure code [CA145] Coolant temperature sensor too low (At left bank only): Excessively low voltage detected 883
Failure code [CA153] Charge temperature sensor too high (At left bank only): Excessively high voltage detected 885
Failure code [CA154] Charge temperature sensor too low (At left bank only): Excessively low voltage detected 887
Failure code [CA187] Sensor power supply (2) abnormally low level (Left bank): Low voltage detection 889
Failure code [CB187] Sensor power supply (2) abnormally low level (Right bank): Low voltage detection 889
Failure code [CA212] Engine oil temperature sensor abnormally high level (At left bank only): High voltage detection 891
Failure code [CA213] Engine oil temperature sensor abnormally low level (At left bank only): Low voltage detection 893
Failure code [CA221] Atmospheric pressure sensor too high (At left bank only): Excessively high voltage detected 895
Failure code [CA222] Atmospheric pressure sensor too low (At left bank only): Excessively low voltage detected 897
Failure code [CA227] Sensor power source (2) too high (Left bank): Excessively high voltage detected 899
Failure code [CB227] Sensor power supply (2) abnormally high level (Right bank): High voltage detection 901
Failure code [CA234] Engine over speed (At left bank only): Excessively high speed 903
Failure code [CA238] Abnormal power source for Ne speed sensor (At left bank only): Excessively low voltage detected 905
Failure code [CB238] Abnormal power source for Ne speed sensor (At right bank only): Excessively low voltage detected 907
Failure code [CA263] Fuel temperature sensor too high (Left bank): Excessively high voltage detected 909
Failure code [CB263] Fuel temperature sensor too high (Right bank): Excessively high voltage detected 911
Failure code [CA265] Fuel temperature sensor abnormally low level (Left bank): Low voltage detection 913
Failure code [CB265] Fuel temperature sensor abnormally low level (Right bank): Low voltage detection 913
Failure code [CA271] PCV1 short circuit (Left bank): Short circuit 914
Failure code [CB271] PCV1 short circuit (Right bank): Short circuit 915
Failure code [CA272] PCV1 disconnection (Left bank): Disconnection 916
Failure code [CB272] PCV1 disconnection (Right bank): Disconnection1 917
Failure code [CA273] PCV2 short circuit (Left bank): Short circuit 918
Failure code [CB273] PCV2 short circuit (Right bank): Short circuit 919
Failure code [CA274] PCV2 disconnection (Left bank): Disconnection 920
Failure code [CB274] PCV2 disconnection (Right bank): Disconnection1 921
Troubleshooting by failure code, Part 4 924
Failure code [CA322] Injector No 1 (L/B No 1) system disconnection or short circuit (Left bank): Disconnection, short circuit 927
Failure code [CA323] Injector No 5 (L/B No 5) system disconnection or short circuit (Left bank): Disconnection, short circuit 929
Failure code [CA324] Injector No 3 (L/B No 3) system disconnection or short circuit (Left bank): Disconnection, short circuit 931
Failure code [CA325] Injector No 6 (L/B No 6) system disconnection or short circuit (Left bank): Disconnection, short circuit 933
Failure code [CA331] Injector No 2 (L/B No 2) system disconnection or short circuit (Left bank): Disconnection, short circuit 935
Failure code [CA332] Injector No 4 (L/B No 4) system disconnection or short circuit (Left bank): Disconnection, short circuit 937
Failure code [CA342] Engine controller data mismatch (Left bank): Mismatch 939
Failure code [CB342] Engine controller data mismatch (Right bank): Mismatch 939
Failure code [CA351] Abnormal injector drive circuit (Left bank): Abnormal circuit 941
Failure code [CB351] Injector drive circuit abnormality (Right bank): Circuit abnormality 943
Failure code [CA352] Sensor power supply (1) abnormally low level (Left bank): Low voltage detection 945
Failure code [CB352] Sensor power supply (1) abnormally low level (Right bank): Low voltage detection 945
Failure code [CA386] Sensor power supply (1) abnormally high level (Left bank): High voltage detection 947
Failure code [CB386] Sensor power supply (1) abnormally high level (Right bank): High voltage detection 949
Failure code [CA431] Trouble in idle validation switch 951
Failure code [CA432] Idle validation action error 955
Failure code [CA441] Power supply voltage abnormally low level (Left bank): Low voltage detection 956
Failure code [CB441] Power supply voltage abnormally low level (Right bank): Low voltage detection 956
Failure code [CA442] Power supply voltage abnormally high level (Left bank): High voltage detection 957
Failure code [CB442] Power supply voltage abnormally high level (Right bank): High voltage detection 957
Failure code [CA449] Common rail abnormally high pressure (2) (Left bank): Abnormally high pressure occurrence 958
Failure code [CB449] Common rail abnormally high pressure (2) (Right bank): Abnormally high pressure occurrence 958
Failure code [CA451] Common rail pressure sensor too high (Left bank): Excessively high voltage detected 959
Failure code [CB451] Common rail pressure sensor abnormally high level (Right bank): High voltage detection 961
Failure code [CA452] Common rail pressure sensor abnormally low level (Left bank): Abnormally low voltage detection 963
Failure code [CB452] Common rail pressure sensor abnormally low level (Right bank): Abnormally low voltage detection 963
Failure code [CA553] Common rail pressure too high (1) (Left bank): Excessively high pressure detected 964
Failure code [CB553] Common rail pressure too high (1) (Right bank): Excessively high pressure detected 965
Failure code [CA554] In-range error in common rail pressure sensor (Left bank): In-range error 966
Failure code [CA559] Loss of pressure feed from supply pump (1) (Left bank): Loss of pressure feed detected 967
Failure code [CB554] In-range error in common rail pressure sensor (Right bank): In-range error 966
Failure code [CA559] Loss of pressure feed from supply pump (1) (Left bank): Loss of pressure feed detected 967
Failure code [CB559] Loss of pressure feed from supply pump (1) (Right bank): Loss of pressure feed detected 971
Failure code [CA689] Abnormal engine Ne speed sensor (Left bank): Abnormal signal 975
Failure code [CB689] Abnormal engine Ne speed sensor (Right bank): Abnormal signal 977
Failure code [CA691] Intake air temperature sensor abnormally high level (At left bank only): High voltage detection 979
Failure code [CA692] Intake air temperature sensor abnormally low level (At left bank only): Low voltage detection 981
Failure code [CA731] Abnormal engine Bkup speed sensor phase (Left bank): Abnormal phase 982
Failure code [CB731] Abnormal engine Bkup speed sensor phase (Right bank): Abnormal phase 982
Troubleshooting by failure code, Part 5 984
Failure code [CA757] Loss of all engine controller data (Left bank): Loss of all data 986
Failure code [CB757] Loss of all engine controller data (Right bank): Loss of all data 986
Failure code [CA778] Abnormal engine Bkup speed sensor (Left bank): Abnormal Bkup signal 987
Failure code [CB778] Engine Bkup speed sensor abnormality (Right bank): Bkup signal error 989
Failure code [CA781] Inter-multicontroller communication error (Left bank): Communication error 991
Failure code [CB781] Inter-multicontroller communication error (Right bank): Communication error 993
Failure code [CA1257] Multicontroller distinction wiring harness key error (Left bank): Distinction error 994
Failure code [CB1257] Multicontroller distinction wiring harness keyerror (Right bank): Distinction error 995
Failure code [CB1548] Injector #7 (R/B #1) system disconnection/shortcircuit (Right bank): Disconnection/Short circuit 997
Failure code [CB1549] Injector #8 (R/B #2) system disconnection/short circuit (Right bank): Disconnection/Short circuit 999
Failure code [CB1551] Injector #10 (R/B #4) system disconnection/short circuit (Right bank): Disconnection/Short circuit 1001
Failure code [CB1552] Injector #11 (R/B #5) system disconnection/short circuit (Right bank): Disconnection/Short circuit 1003
Failure code [CB1553] Injector #12 (R/B #6) system disconnection/short circuit (Right bank): Disconnection/Short circuit 1005
Failure code [CB1622] Injector #9 (R/B #3) system disconnection/short circuit (Right bank): Disconnection/Short circuit 1007
Failure code [CA1633] KOMNET abnormality (Left bank): Communication error 1009
Failure code [CA2185] Throttle sensor supply voltage high error 1011
Failure code [CA2186] Throttle sensor power supply low error 1013
Failure code [CA2249] Loss of pressure feed from supply pump (2) (Left bank): Loss of pressure feed detected 1014
Failure code [CB2249] Loss of pressure feed from supply pump (2) (Right bank): Loss of pressure feed detected 1014
Failure code [CA2555] Intake heater relay voltage low error (Left bank) 1015
Failure code [CA2556] Intake heater relay voltage high error (Left bank)1 1017
Troubleshooting by failure code, Part 6 1020
Failure code [D180KA] Preheating relay output system: Disconnection 1023
Failure code [D180KB] Preheating relay output system: Grounding fault 1024
Failure code [D180KY] Preheating relay output system: Hot short circuit 1025
Failure code [D19HKB] Stop lamp relay output system: Short circuit 1027
Failure code [D1EFKA] Pre-lubrication start relay output system: Disconnection 1029
Failure code [D1EFKB] Pre-lubrication start relay output system: Grounding fault 1031
Failure code [D1EFKY] Pre-lubrication start relay output system: Hot short circuit 1033
Failure code [D1EMKA] Disconnection of Parking Interlock Relay Output Circuit 1035
Failure code [D1EMKB] Ground Fault of Parking Interlock Relay Output Circuit 1036
Failure code [D1EMKY] Hot Short of Parking Interlock Relay Output Circuit 1037
Failure code [D1ENKZ] Failure of Power Ladder Power Supply Relay Output System 1038
Failure code [D1EPKA] Disconnection of Power Ladder Pump Drive Relay Output Circuit 1039
Failure code [D1EPKB] Ground Fault of Power Ladder Pump Drive Relay Output Circuit 1040
Failure code [D1EPKY] Hot Short of Power Ladder Pump Drive Relay Output Circuit 1041
Failure code [D1EQKA] Disconnection of Power Ladder Buzzer Relay Output Circuit 1042
Failure code [D1EQKB] Ground Fault of Power Ladder Buzzer Relay Output Circuit 1043
Failure code [D1EQKY] Hot Short of Power Ladder Buzzer Relay Output Circuit 1044
Failure code [D1ERKA] Open Circuit in Power Ladder Raise Solenoid Relay Output Circuit 1045
Failure code [D1ERKB] Ground Fault of Power Ladder Raise Solenoid Relay Output Circuit 1046
Failure code [D1ERKY] Hot Short in Power Ladder Raise Solenoid Relay Output Circuit 1047
Failure code [D1ESKA] Open Circuit in Power Ladder Lower Solenoid Relay Output Circuit 1048
Failure code [D1ESKB] Ground Fault of Power Ladder Lower Solenoid Relay Output Circuit 1049
Failure code [D1ESKY] Hot Short in Power Ladder Lower Solenoid Relay Output Circuit 1050
Failure code [DAF9KM] Wrong connection of connector 1051
Failure code [DAFRKR] Abnormal CAN communication (machine monitor): Abnormal communication 1052
Failure code [DAQ0KK] Transmission controller direct power supply: Lowering of power supply voltage 1053
Failure code [DAQ0KT] Transmission controller nonvolatile memory: Abnormality in controller 1055
Failure code [DAQ2KK] Transmission controller solenoid power supply: Power supply voltage too low 1057
Failure code [DAQ9KQ] Transmission controller: Disagreement of model selection 1059
Failure code [DAQRKR] Abnormality in CAN communication (Transmission) 1060
Failure code [DAQRMA] Transmission controller option setting: Malfunction 1065
Failure code [DB10KT] Retarder controller nonvolatile memory: Abnormality in controller 1065
Failure code [DB12KK] Retarder controller solenoid power supply: Power supply system trouble 1066
Failure code [DB13KK] Retarder controller battery direct power supply: Power supply voltage too low 1068
Failure code [DB19KQ] Disagreement of model selection (Retarder controller) 1070
Failure code [DB1RKR] CAN communication (retarder controller): Communication disabled 1071
Failure code [DB1RMA] Disagreement of option setting (Retarder controller) 1075
Failure code [DB2RKR] CAN communication (engine controller): Communication disabled 1076
Failure code [dB2RKR] CAN communication (engine controller): Communication disabled 1084
Failure code [DBB0KK] or VHMS_LED display: “n9” -> “01” VHMS controller: Low power supply voltage (input) 1091
Failure code [DBB0KQ] (or VHMS_LED display: “nF” -> “11”) VHMS controller: Disagreement of model selection signals 1093
Failure code [DBB3KK] (or VHMS_LED display: “n9” -> “05”) VHMS controller battery power supply: Low power supply voltage (input) 1095
Failure code [DBB5KP] (or VHMS_LED display: “n9” -> “04”) VHMS controller 5 V power supply output: Low output voltage 1097
Failure code [DBB6KP] (or VHMS_LED display: “n9” -> “02”) VHMS controller 24 V power supply output: Low output voltage 1099
Failure code [DBB7KP] (or VHMS_LED display: “n9” -> “03”) VHMS controller 12 V power supply output: Low output voltage 1101
Failure code [DBBQKR] (or VHMS_LED display: “n8” -> “02”) VHMS controller CAN communication: Defective communication (Abnormality in target component system) 1102
Failure code [DBC0KT] Abnormality of Non-volatile Memory 1103
Failure code [DBC2KK] ABS controller solenoid power supply: Power supply system trouble 1105
Failure code [DBC2KK] Solenoid Power Supply: Low Voltage 1107
Failure code [DBC3KK] ABS controller battery direct power supply: Power supply voltage too low 1109
Failure code [DBC3KK] Direct Battery Power Supply: Low Voltage 1111
Failure code [DBC9KQ] Disagreement of model selection (ABS controller) 1113
Failure code [DBCRKR] Abnormality in CAN communication (ABS) 1114
Failure code [DBCRMA] Disagreement of option setting (ABS controller) 1118
Failure code [DBG2KK] Solenoid power supply: Low voltage 1119
Failure code [DBG3KK] Battery direct power supply: Low voltage 1121
Failure code [DBG9KQ] Model selection signal: Abnormal 1123
Failure code [DDD7KX] Trouble in travel speed setting switch system: Out of input signal range 1125
Failure code [DDD8KA] ARSC system switch system: Disconnection (If equipped) 1127
Failure code [DDD8KB] ARSC system switch system: Short circuit (If equipped) 1129
Failure code [DDD9KA] ABS system switch system: Disconnection 1131
Failure code [DDD9KB] ABS system switch system: Short circuit 1133
Failure code [DDDAKA] ASR system switch: Disconnection 1135
Failure code [DDDAKB] ASR system switch: Short circuit 1137
Failure code [DDDGL4] Failure of ladder manual operation switch CH1 (inside cab) system 1139
Failure code [DDDHL4] Failure of ladder manual operation switch CH2 (outside cab) system 1141
Failure code [DDE2KB] Engine oil pressure switch error: Grounding fault 1143
Failure code [DDE2L6] Engine oil pressure switch error: Disconnection or hot short circuit 1145
Failure code [DDP6L4] Service brake pressure switch trouble (Rear) 1147
Failure code [DDTHKA] Hi clutch fill switch: Disconnection 1149
Failure code [DDTJKA] Lo clutch fill switch: Disconnection 1151
Failure code [DDTKKA] 1st clutch fill switch: Disconnection 1153
Failure code [DDTLKA] 2nd clutch fill switch: Disconnection 1155
Failure code [DDTMKA] 3rd clutch fill switch: Disconnection 1157
Failure code [DDTNKA] R clutch fill switch: Disconnection 1159
Failure code [DDTPKA] 4th clutch fill switch: Disconnection 1161
Failure code [DDU1KA] Open Circuit in Parking Brake Operation Input Circuit 1163
Failure code [DF10KA] Gear shift lever: Disconnection 1164
Failure code [DF10KB] Gear shift lever: Short circuit 1167
Failure code [DGE5KX] or VHMS_LED display: “n4” -> “01” Atmospheric temperature sensor: Out of input signal range 1171
Failure code [DGF1KX] Transmission oil temperature sensor: Out of input signal range 1173
Failure code [DGR2KB] Trouble in retarder oil temperature sensor (rear wheel) system (Disconnection and short circuit) 1175
Failure code [DGR2KZ] Trouble in retarder oil temperature sensor (rear wheel) system (Ground fault) 1177
Failure code [DGR4KB] Trouble in retarder oil temperature sensor (front wheel) system (Disconnection and short circuit) 1178
Failure code [DGR4KZ] Trouble in retarder oil temperature sensor (front wheel) system (Ground fault) 1179
Failure code [DGR6KX] Steering oil temperature sensor: Input signal out of range 1181
Failure code [DGT1KX] Torque converter oil temperature sensor: Out of input signal range 1183
Troubleshooting by failure code, Part 7 1186
Failure code [DGT5KA] (or VHMS_LED display: “n3” -> “12”) Left bank exhaust temperature sensor system (Front): Disconnection 1188
Failure code [dGT5KA] (or VHMS_LED display: “n3” -> “22”) Left bank exhaust temperature sensor system (Rear): Disconnection 1191
Failure code [DGT5KB] (or VHMS_LED display: “n3” -> “11”) Left bank exhaust temperature sensor system (Front): Short circuit 1194
Failure code [dGT5KB] (or VHMS_LED display: “n3” -> “21”) Left bank exhaust temperature sensor system (Rear): Short circuit 1197
Failure code [DGT6KA] (or VHMS_LED display: “n3” -> “24”) Right bank exhaust temperature sensor system (Front): Disconnection 1200
Failure code [dGT6KA] (or VHMS_LED display: “n3” -> “26”) Right bank exhaust temperature sensor system (Rear): Disconnection 1203
Failure code [DGT6KB] (or VHMS_LED display: “n3” -> “23”) Right bank exhaust temperature sensor system (Front): Short circuit 1206
Failure code [dGT6KB] (or VHMS_LED display: “n3” -> “25”) Right bank exhaust temperature sensor system (Rear): Short circuit 1209
Failure code [DHE5KB] or VHMS_LED display: “n3” -> “32” Blow-by pressure sensor: Short circuit 1212
Failure code [DHE5KY] or VHMS_LED display: “n3” -> “31” Blow-by pressure sensor: Short circuit with power supply line 1215
Failure code [DHP4KY] or VHMS_LED display: “n5” -> “44” Short circuit in suspension pressure sensor system (Front right) 1217
Failure code [DHP4KZ] or VHMS_LED display: “n5” -> “43” Disconnectionor ground fault in suspension pressure sensor system(Front right) 1219
Failure code [DHP5KY] or VHMS_LED display: “n5” -> “54” Short circuit in suspension pressure sensor system (Front left) 1221
Failure code [DHP5KZ] or VHMS_LED display: “n5” -> “53” Disconnectionor ground fault in suspension pressure sensor system(Front left) 1223
Failure code [DHP6KA] Suspension pressure sensor system: Disconnection (Right rear) 1225
Failure code [DHP6KX] Failure in suspension pressure sensor system trouble: Out of input signal range (Right rear) 1226
Failure code [DHP6KY] or VHMS_LED display: “n5” -> “64” Suspension pressure sensor system: Short circuit (Right rear) 1229
Failure code [DHP6KZ] or VHMS_LED display: “n5” -> “63” Suspension pressure sensor system: Disconnection or ground fault (Right rear) 1231
Failure code [DHP7KA] Suspension pressure sensor system: Disconnection (Left rear) 1233
Failure code [DHP7KX] Failure in suspension pressure sensor system trouble: Out of input signal range (Left rear) 1234
Failure code [DHP7KY] or VHMS_LED display: “n5” -> “74” Suspension pressure sensor system: Short circuit (Left rear) 1237
Failure code [DHP7KZ] or VHMS_LED display: “n5” -> “73” Suspension pressure sensor system: Disconnection or ground fault (Left rear) 1239
Failure code [DHT5KX] Torque converter oil pressure sensor: Out of input signal range 1241
Failure code [DHT5L6] Torque converter oil pressure sensor: Disagreement of run and stop condition with signal 1243
Failure code [DHU2KX] Front accumulator oil pressure sensor: Out of input signal range 1245
Failure code [DHU3KX] Rear accumulator oil pressure sensor: Out of input signal range 1247
Failure code [DHU6KX] Trouble in ABS control valve pressure sensor (Front right) 1249
Failure code [DHU7KX] Trouble in ABS control valve pressure sensor (Front left) 1251
Failure code [DHU8KX] Trouble in ABS control valve pressure sensor (Front right) 1253
Failure code [DHU9KX] Trouble in ABS control valve pressure sensor (Front right) 1255
Failure code [DJF1KA] Fuel level sensor: Disconnection 1257
Failure code [DK30KX] Steering angle potentiometer: Trouble (Disconnection) 1259
Failure code [DK51L5] Retarder lever potentiometer: Potentiometer signal is inconsistent with swich signal 1260
Failure code [DK52KX] Failure in hoist lever potentiometer 1: Out of input signal range 1263
Failure code [DK53L8] Failure in hoist lever potentiometer 2: Disagreement of analog signal 1265
Failure code [DK54KX] Body positioner sensor: Out of input signal range 1267
Failure code [DK5VKX] Abnormality of Power Ladder Position Input Signal (Out of Range) 1269
Failure code [DK5VMA] Power Ladder System Abnormality 1271
Failure code [DKD0L6] Failure in steering speed sensor 1273
Failure code [DKH0KX] Clinometer sensor signal out of range 1275
Failure code [DKH1KX] (or VHMS_LED display: “n4″->”33”) Abnormality in clinometer sensor 1277
Failure code [DLF1KA] Transmission input shaft speed sensor: Disconnection 1279
Failure code [DLF1LC] Transmission input shaft speed sensor: Disagreement of revolution speed signal 1281
Failure code [DLF2KA] Transmission intermediate shaft speed sensor: Disconnection 1283
Failure code [DLF2LC] Transmission intermediate shaft speed sensor: Disagreement of revolution speed signal 1285
Troubleshooting by failure code, Part 8 1288
Failure code [DLF6KA] Disconnection in wheel speed sensor (Front right) 1291
Failure code [DLF6L3] Trouble in wheel speed sensor (Front right) 1293
Failure code [DLF7KA] Disconnection in wheel speed sensor (Front left) 1295
Failure code [DLF7L3] Trouble in wheel speed sensor (Front left) 1297
Failure code [DLF8KA] Wheel speed sensor: Disconnection (Rear right) 1299
Failure code [DLF8L3] Wheel speed sensor: Disconnection (Rear right) 1301
Failure code [DLF8LC] Wheel speed sensor: Trouble (Rear right) 1303
Failure code [DLF8MA] Wheel speed sensor: Disconnection (Rear right) 1303
Failure code [DLF9KA] Wheel speed sensor: Disconnection (Rear left) 1305
Failure code [DLF9L3] Wheel speed sensor: Trouble (Rear left) 1307
Failure code [DLF9LC] Wheel speed sensor: Trouble (Rear left) 1309
Failure code [DLF9MA] Wheel speed sensor: Disconnection (Rear left) 1309
Failure code [DLT3KA] Transmission output shaft speed sensor: Disconnection 1311
Failure code [DLT3LC] Transmission output shaft speed sensor: Disagreement of revolution speed signal 1313
Failure code [DLT4KA] Transmission output shaft speed sensor: Disconnection 1315
Failure code [DLT4MA] Transmission output shaft speed sensor: Disconnection 1317
Failure code [DUM7KY] Pre-lubrication operation lamp output abnormality: Hot short circuit 1319
Failure code [DUM7KZ] Pre-lubrication operation lamp output abnormality: Disconnection or grounding fault 1321
Failure code [DUM9KZ] Failure of power ladder indicator system 1323
Failure code [DV00KB] Buzzer output: Short circuit 1325
Failure code [DW2AKA] Main pressure variable valve output: Disconnection 1327
Failure code [DW2AKB] Main pressure variable valve output circuit: Ground fault 1329
Failure code [DW2AKY] Main pressure variable valve output circuit: Hot short 1331
Failure code [DW2AL1] Main pressure variable valve: Defective reset 1333
Failure code [DW2ALH] Main pressure variable valve: Malfunction 1335
Failure code [DW2BKA] Main oil level selector valve output: Disconnection 1336
Failure code [DW2BKB] Main oil level selector valve output circuit: Ground fault 1337
Failure code [DW2BKY] Main oil level selector valve output circuit: Hot short 1339
Failure code [DW2BL1] Main oil level selector valve: Defective reset 1341
Failure code [DW2BLH] Main oil level selector valve: Malfunction 1343
Failure code [DW2CKA] Transmission lubrication variable valve output: Disconnection 1344
Failure code [DW2CKB] Transmission lubrication variable valve output circuit: Ground fault 1345
Failure code [DW2CKY] Transmission lubrication variable valve output circuit: Hot short 1347
Failure code [DW2CL1] Transmission lubrication variable valve: Defective reset 1349
Failure code [DW2CLH] Transmission lubrication variable valve: Malfunction 1351
Failure code [DW35KZ] Failure in output system of auto suspension solenoid 1: Disconnection or short circuit 1353
Failure code [DW36KZ] Failure in output system of auto suspension solenoid 2: Disconnection or short circuit 1355
Failure code [DW71KZ] Exhaust brake output system trouble (Disconection/Ground fault/Hot short) 1357
Failure code [DW72KZ] Kick-out solenoid output system trouble: Disconnection or short circuit 1359
Failure code [DW73KZ] Failure in hoist select valve output system: Disconnection or short circuit 1361
Failure code [DW78KZ] Brake cooling valve (BCV) (rear wheel) output system trouble: Disconnection or short circuit 1363
Failure code [DWNBK4] ASR shut-off valve: Trouble (Valve keeps operating) 1365
Failure code [DWNBKA] ASR shut-off valve output circuit: Disconnection 1367
Failure code [DWNBKB] ASR shut-off valve output circuit: Ground fault 1369
Failure code [DWNBKY] ASR shut-off valve output circuit: Short circuit 1371
Failure code [DWNBMA] ASR shut-off valve: Trouble (Valve does not operate) 1372
Failure code [DWNDKZ] Trouble in ABS cut-off valve (Front) system 1373
Failure code [DWNDMA] Defective ABS cut-off valve (Front) 1375
Failure code [DWNEKZ] Trouble in ABS cut-off valve (Rear) system 1377
Failure code [DWNEMA] Defective ABS cut-off valve (Rear) 1379
Failure code [DWNLKA] Open Circuit in Power Ladder Shock Reducing Solenoid Output Circuit 1381
Failure code [DWNLKB] Ground Fault of Power Ladder Shock Reducing Solenoid Output Circuit 1382
Failure code [DWNLKY] Hot Short in Power Ladder Shock Reducing Solenoid Output Circuit 1383
Troubleshooting by failure code, Part 9 1386
Failure code [DX11K4] Rear brake proportional pressure reducing solenoid valve: Out of control 1389
Failure code [DX11KA] Rear brake proportional pressure reducing solenoid valve output circuit: Disconnection 1391
Failure code [DX11KB] Rear brake proportional pressure reducing solenoid valve: Short circuit 1392
Failure code [DX11KY] Rear brake proportional pressure reducing solenoid valve: Short circuit to power source line 1393
Failure code [DX11MA] Rear brake proportional pressure reducing solenoid valve: Malfunction 1395
Failure code [DX12K4] Front brake proportional pressure reducing solenoid valve: Out of control 1397
Failure code [DX12KA] Front brake proportional pressure reducing solenoid valve output circuit: Disconnection 1399
Failure code [DX12KB] Front brake proportional pressure reducing solenoid valve: Short circuit 1400
Failure code [DX12KY] Front brake proportional pressure reducing solenoid valve: Short circuit to power source line 1401
Failure code [DX12MA] Front brake proportional pressure reducing solenoid valve: Malfunction 1403
Failure code [DX13KA] Output circuit of hoist EPC valve: Disconnection 1405
Failure code [DX13KB] Output circuit of hoist EPC valve: Short circuit 1407
Failure code [DX13KY] Output circuit of hoist EPC valve: Short circuit with power source line 1409
Failure code [DX17K4] ASR proportional pressure reducing solenoid valve (right): Trouble (Valve keeps operating) 1411
Failure code [DX17KA] ASR proportional pressure reducing solenoid valve (right) output circuit: Disconnection 1413
Failure code [DX17KB] ASR proportional pressure reducing solenoid valve (right) output circuit: Ground fault 1415
Failure code [DX17KY] ASR proportional pressure reducing solenoid valve (right) output circuit: Short circuit 1417
Failure code [DX17MA] ASR proportional pressure reducing solenoid valve (right): Trouble (Valve does not operate) 1417
Failure code [DX18K4] ASR proportional pressure reducing solenoid valve (left): Trouble (Valve keeps operating) 1419
Failure code [DX18KA] ASR proportional pressure reducing solenoid valve (left) output circuit: Disconnection 1421
Failure code [DX18KB] ASR proportional pressure reducing solenoid valve (left) output circuit: Ground fault 1423
Failure code [DX18KY] ASR proportional pressure reducing solenoid valve (left) output circuit: Short circuit 1425
Failure code [DX18MA] ASR proportional pressure reducing solenoid valve (left): Trouble (Valve does not operate) 1425
Failure code [DX21KA] Disconnection in ABS control valve output circuit (Front right) 1426
Failure code [DX21KB] Ground fault in ABS control valve output circuit (Front right) 1427
Failure code [DX21KY] Hot short in ABS control valve output circuit (Front right) 1428
Failure code [DX21MA] Defective ABS control valve (Front right) 1429
Failure code [DX22KA] Disconnection in ABS control valve output circuit (Front left) 1430
Failure code [DX22KB] Ground fault in ABS control valve output circuit (Front left) 1431
Failure code [DX22KY] Hot short in ABS control valve output circuit (Front left) 1432
Failure code [DX22MA] Defective ABS control valve (Front left) 1433
Failure code [DX23KA] Disconnection in ABS control valve output circuit (Rear right) 1434
Failure code [DX23KB] Ground fault in ABS control valve output circuit (Rear right) 1435
Failure code [DX23KY] Hot short in ABS control valve output circuit (Rear right) 1436
Failure code [DX23MA] Defective ABS control valve (Rear right) 1437
Failure code [DX24KA] Disconnection in ABS control valve output circuit (Rear left) 1438
Failure code [DX24KB] Ground fault in ABS control valve output circuit (Rear left) 1439
Failure code [DX24KY] Hot short in ABS control valve output circuit (Rear left) 1440
Failure code [DX24MA] Defective ABS control valve (Rear left) 1441
Failure code [DX25MA] Defective ABS front wheel system control valve 1442
Failure code [DX26MA] Defective ABS rear wheel system control valve 1442
Troubleshooting by failure code, Part 10 1444
Failure code [DXH1KA] Lockup clutch solenoid output circuit: Disconnection 1447
Failure code [DXH1KB] Lockup clutch solenoid output circuit: Short circuit 1449
Failure code [DXH1KY] Lockup clutch solenoid output circuit: Short circuit to power supply line 1451
Failure code [DXH2KA] Hi clutch solenoid output circuit: Disconnection 1453
Failure code [DXH2KB] Hi clutch solenoid output circuit: Short circuit 1455
Failure code [DXH2KY] Hi clutch solenoid output circuit: Short circuit to power supply line 1457
Failure code [DXH3KA] Lo clutch solenoid output circuit: Disconnection 1461
Failure code [DXH3KB] Lo clutch solenoid output circuit: Short circuit 1463
Failure code [DXH3KY] Lo clutch solenoid output circuit: Short circuit in power supply line 1465
Failure code [DXH4KA] 1st clutch solenoid output circuit: Disconnection 1469
Failure code [DXH4KB] 1st clutch solenoid output circuit: Short circuit 1471
Failure code [DXH4KY] 1st clutch solenoid output circuit: Short circuit to power supply line 1473
Failure code [DXH5KA] 2nd clutch solenoid output circuit: Disconnection 1477
Failure code [DXH5KB] 2nd clutch solenoid output circuit: Short circuit 1479
Failure code [DXH5KY] 2nd clutch solenoid output circuit: Short circuit in power supply line 1481
Failure code [DXH6KA] 3rd clutch solenoid output circuit: Disconnection 1485
Failure code [DXH6KB] 3rd clutch solenoid output circuit: Short circuit 1487
Failure code [DXH6KY] 3rd clutch solenoid output circuit: Short circuit to power supply line 1489
Failure code [DXH7KA] R clutch solenoid output circuit: Disconnection 1493
Failure code [DXH7KB] R clutch solenoid output circuit: Short circuit 1495
Failure code [DXH7KY] R clutch solenoid output circuit: Short circuit to power supply line 1497
Failure code [DXHHKA] 4th clutch solenoid output circuit: Disconnection 1499
Failure code [DXHHKB] 4th clutch solenoid output circuit: Short circuit 1501
Failure code [DXHHKY] 4th clutch solenoid output circuit: Short circuit to power supply line 1503
Failure code [F@BBZL] or VHMS_LED display: “n3” -> “38” Blow-by pressure: High error 1506
Failure code [F@BYNS] (or VHMS_LED display “n3” -> “61”) Left front exhaust temperature sensor (1): Exhaust temperature abnormal rise 1507
Failure code [f@BYNS] (or VHMS_LED display “n3” -> “71”) Left rear exhaust temperature sensor (1): Exhaust temperature abnormal rise 1509
Failure code [F@BZNS] (or VHMS_LED display “n3” -> “81”) Right front exhaust temperature sensor (1): Exhaust temperature abnormal rise 1511
Failure code [f@BZNS] (or VHMS_LED display “n3” -> “91”) Right rear exhaust temperature sensor (1): Exhaust temperature abnormal rise 1513
Troubleshooting of electrical system (E-mode) 1524
Before troubleshooting of electric system 1526
Contents of troubleshooting table 1527
E-1 Engine does not start 1528
E-2 Automatic preheating does not operate 1531
E-3 Machine monitor does not display all, when starting switch is turned ON 1535
E-4 Machine monitor does not operate when starting switch is OFF 1537
E-5 Alarm buzzer does not sound 1539
E-6 Alarm buzzer does not stop sounding 1541
E-7 Gauges of machine monitor, caution lamps or character display section do not display properly 1542
E-8 A selection of the display in character display section cannot be changed 1544
E-9 Power mode selecting function does not operate properly 1547
E-10 AISS function does not operate properly 1548
E-11 Seat belt caution lamp does not display properly 1549
E-12 Turn signal lamp or turning lamp (hazard lamp) do not work properly 1550
E-13 Night illumination (lighting) does not work properly 1553
E-14 Emergency steering does not operate 1565
E-15 Hoist lever does not operate normally 1570
E-16 Power supply system (Air conditioner does not operate) 1573
E-17 Compressor and refrigerant system (Air is not cooled) 1575
E-18 Blower motor system (Air does not come out or air flow is abnormal) 1577
E-19 Ladder cannot be lowered with operation switch outside cab 1579
E-20 Ladder cannot be lowered with operation switch inside cab 1580
E-21 Ladder continues lowering 1581
E-22 Ladder cannot be raised with operation switch outside cab 1582
E-23 Ladder cannot be lowered with operation switch inside cab 1583
E-24 Ladder continues rising 1584
E-25 Buzzer does not sound when power ladder is operated 1585
E-26 Power ladder pump does not operate 1586
Troubleshooting of hydraulic and mechanical system (H-mode) 1588
Contents of troubleshooting table 1590
H-1 Machine does not start 1591
H-2 Machine does not travel smoothly (hunting) 1593
H-3 Lockup cannot be cancelled 1593
H-4 Excessive shock when starting or shifting excessive 1594
H-5 Transmission does not shift up 1595
H-6 Machine lacks power or speed when traveling 1597
H-7 Time lag is excessive when starting or shifting gear 1601
H-8 Torque converter oil temperature is high 1603
H-9 Torque converter oil pressure is low 1604
H-10 Front brake is ineffective 1605
H-11 Rear brake is ineffective 1606
H-12 Steering wheel is heavy 1607
H-13 Steering wheel does not work 1608
H-14 Steering wheel vibrates 1609
H-15 Dump body lifting speed is slow 1610
H-16 Dump body does not work 1611
H-17 Excessive hydraulic drift of dump body 1612
H-18 Power ladder does not move or its speed is low 1613
Troubleshooting of engine (S-mode) 1616
Method of using troubleshooting charts 1618
S-1 Starting performance is poor1 1621
S-2 Engine does not start 1622
S-3 Engine does not pick up smoothly 1625
S-4 Engine stops during operations 1626
S-5 Engine does not rotate smoothly 1627
S-6 Engine lacks output (or lacks power) 1628
S-7 Exhaust smoke is black (incomplete combustion) 1630
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1631
S-9 Oil becomes contaminated quickly 1632
S-10 Fuel consumption is excessive 1633
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1 1634
S-12 Oil pressure drops 1635
S-13 Oil level rises (Entry of coolant or fuel) 1636
S-14 Coolant temperature becomes too high (overheating) 1637
S-15 Abnormal noise is made 1638
S-16 Vibration is excessive 1639
50 Disassembly and assembly 0
General information on disassembly and assembly 0
How to read this manual 0
Coating materials list 0
Special tool list 0
Sketches of special tools 0
Engine and cooling system 0
Removal and installation of fuel supply pump assembly 0
Removal and installation of fuel injector assembly 0
Removal and installation of cylinder head assembly 0
Removal and installation of engine hood assembly 0
Removal and installation of radiator assembly 0
Removal and installation of engine assembly 0
Removal and installation of engine front oil seal 0
Removal and installation of engine rear oil seal 0
Power train, Part 1 0
Removal and installation of front drive shaft 0
Removal and installation of rear drive shaft 0
Removal and installation of output shaft assembly 0
Disassembly and assembly of damper assembly 0
Removal and installation of torque converter and transmission assembly 0
Disconnection and connection of torque converter assembly and transmission assembly 0
Disassembly and assembly of torque converter PTO assembly 0
Disassembly and assembly of transmission assembly 0
Power train, Part 2 0
Removal and installation of final drive carrier assembly 0
Disassembly and assembly of final drive carrier assembly 0
Removal and installation of differential assembly 0
Disassembly and assembly of differential assembly 0
Steering system 0
Removal and installation of steering cylinder assembly 0
Disassembly and assembly of steering cylinder assembly 0
Removal and installation of steering valve assembly 0
Disassembly and assembly of steering valve assembly 0
Brake system 0
Removal and installation of front wheel hub and brake assembly 0
Disassembly and assembly of front wheel hub and brake assembly 0
Removal and installation of final drive and rear brake assembly 0
Disassembly and assembly of final drive and rear brake assembly 0
Undercarriage and frame 0
Removal and installation of front wheel assembly 0
Removal and installation of rear wheel assembly 0
Removal and installation of front suspension cylinder assembly 0
Disassembly and assembly of front suspension cylinder assembly (cylinder with buffer ring) 0
Removal and installation of king pin 0
Removal and installation of rear suspension cylinder assembly 0
Disassembly and assembly of rear suspension cylinder assembly 0
Hydraulic system 0
Removal and installation of hoist valve assembly 0
Disassembly and assembly of hoist valve assembly 0
Disassembly and assembly of hoist cylinder assembly 0
Body 0
Removal and installation of body assembly 0
Cab and its attachments 0
Disassembly and assembly of operator’s seat assembly 0
Removal and installation of air conditioner unit assembly 0
Electrical system 0
Removal and installation of engine controller assembly 0
Removal and installation of transmission controller assembly 0
Removal and installation of retarder controller assembly 0
Removal and installation of ABS controller assembly 0
Removal and installation of VHMS controller assembly 0
90 Diagrams and drawings 0
Hydraulic diagrams and drawings 1894
Power train hydraulic circuit diagram 1896
Steering and hoist hydraulic circuit diagram 1897
Brake hydraulic circuit diagram 1898
Brake hydraulic circuit diagram (ASR specification) 1899
Brake hydraulic circuit diagram (ABS specification) 1900
Brake hydraulic circuit diagram (ASR and ABS specification) 1901
Hydraulic circuit diagram for power ladder 1902
Electrical diagrams and drawings 1904
Electrical circuit diagram for outside cab 1906
Electrical circuit diagram for inside cab 1910
Electrical circuit diagram for ABS (Outside cab) (If equipped) 1918
Electrical circuit diagram for ABS (Inside cab) (If equipped) 1919
Electrical circuit diagram for ASR (If equipped) 1920
Electrical circuit diagram for power ladder 1921
Air conditioner electrical circuit diagram 1922
Electrical circuit diagram for auto greasing (If equipped) 1923
Electrical circuit diagram of external power supply heater 1924
Back Cover 1927

DESCRIPTION:

Komatsu HD 785-7 Dump Truck Shop Manual SEN05900-01-N1-00 – PDF DOWNLOAD 

SERIAL NUMBERS N10561 and up

HOW TO READ THE SHOP MANUAL:
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

S.V 30/12/24