Komatsu HD785-7 Galeo Dump Truck (7001 and up) Shop Manual - SEN01274-03

This complete service repair workshop manual PDF download for the Komatsu HD785-7 Galeo Dump Truck (SN: 7001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.

APPLICABLE MODELS :

Komatsu HD785-7
Serial Numbers : 7001 and up

TABLE OF CONTENTS :

00. Index and foreword
01. Specification
10. Structure and function
20. Standard value table
30. Testing and adjusting
40. Troubleshooting
50. Disassembly and assembly
90. Diagrams and drawings

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEN01274-03
Total Pages : 1491

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00 Index and foreword
Index
Composition of shop manual
Table of contents
Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling electric equipment and hydraulic component
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table

01 Specification
Specification and technical data
Specification drawing
Specifications
Weight table
Fuel, coolant and lubricants

10 Structure, function and maintenance standard
Engine and cooling system
Radiator, brake, torque converter oil cooler, after cooler, steering, hoist oil cooler
Fuel system
Power train, Part 1
Power train skeleton
Output shaft
Drive shaft
Torque converter and transmission hydraulic piping
Brake cooling oil control valve (BCV)
Torque converter
Torque converter valve
Transmission
Transmission control valve
ECMV
Lubricating oil amount selector valve
Power train, Part 2
Axle
Differential
Final drive
Wheels
Steering system
Steering column
Steering linkage
Brake system
Brake piping
Brake valve
Secondary brake valve
Accumulator charge valve
Accumulator
Slack adjuster
Brake, parking brake
Parking brake solenoid
Exhaust brake
Undercarriage and frame
Suspension
Suspension cylinder
Rear axle support
Hydraulic system
Steering and hoist hydraulic piping
Steering, hoist filter (high pressure circuit)
Dump body control
Hydraulic tank
Steering valve
Crossover relief valve
Steering cylinder
Steering control valve
Hoist valve
Dump control valve (EPC valve)
Hoist cylinder
Hydraulic pump
Cab and its attachments
ROPS cab
Air conditioner
Rear view monitor
Controller related
Electrical system, Part 1
Machine monitor system
Electrical system, Part 2
Automatic shift control system
Automatic emergency steering system
Automatic suspension system
Retarder control system
Dump control lever
Electrical system, Part 3
VHMS controller related
ABS/ASR system
Altitude setting function
Electrical system, Part 4
Sensors, switches

20 Standard value table
Standard service value table
Standard value table for engine
Standard value table for machine

30 Testing and adjusting
Testing and adjusting, Part 1
Testing and adjusting tools list
Testing engine speed
Testing air supply pressure (boost pressure)
Testing exhaust temperature
Testing exhaust gas color
Adjustment of valve clearance
Testing compression pressure
Testing blow-by pressure
Testing engine oil pressure
Handling of fuel system devices
Releasing residual pressure from fuel system
Testing fuel pressure
Reduced cylinder mode operation
No-injection cranking
Testing leakage-from pressure limiter and return rate from injector
Bleeding air from fuel circuit (Standard spec.)
Bleeding air from fuel circuit (Extra low-grade fuel spec.)
Testing the fuel circuit for leakage
Replacement and adjustment of fan belt
Testing and adjusting alternator belt tension
Testing and adjusting air conditioner compressor belt
Testing and adjusting, Part 2
Testing torque converter stall speed
Testing power train oil pressure
Adjusting transmission speed sensor
Testing and adjusting brake oil pressure
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas
Testing brake performance
Bleeding air from brake circuit
Bleeding air from ASR circuit (if equipped)
Testing wear of front brake disc
Testing wear of rear brake disc
Method of releasing parking brakein an emergency
Testing and adjusting front suspension cylinder
Testing and adjusting rear suspension cylinder
Testing and adjusting front suspension cylinder (Automatic suspension specification)
Testing and adjusting hydraulic pressure in steering, hoist circuit
Testing and adjusting oil pressure in dump EPC circuit
Air bleeding from steering cylinder
Procedure for raising dump body in emergency
Adjusting body positioner sensor
Handling of voltage circuit of engine controller
Adjusting transmission controller
Method for emergency escape at electrical system failure
Testing and adjusting, Part 3
Setting and adjusting of devices
Special functions of machine monitor (EMMS)
Testing and adjusting, Part 4
Special functions of machine monitor (EMMS)
Testing and adjusting, Part 5
VHMS controller initial setting procedure
Precautions for replacing VHMScontroller
Pm Clinic check sheet
Initial setting of payload meter
Setting of payload meter built in VHMS

40 Troubleshooting
Failure code table and fuse locations
Failure codes table
Fuse locations
General information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Check before troubleshooting
Classification and procedures for troubleshooting
Contents of troubleshooting table
Connection table for connector pin numbers
T-adapter box and T-adapter table
Troubleshooting by failure code, Part 1
Failure code [1500L0] Dual engagement
Failure code [15B0NX] Transmission oil filter: Clogging
Failure code [15F0KM] R o F shifting abuse 1: Mistake in operation
Failure code [15F0MB] R o F shifting abuse 2: Mistake in operation
Failure code [15F7KM] Forward clutch disk abuse: Mistake in operation or setting
Failure code [15G0MW] R clutch: Slipping
Failure code [15G7KM] Reverse clutch disk abuse: Mistake in operation or setting
Failure code [15H0MW] Hi clutch: Slipping
Failure code [15J0MW] Lo clutch: Slipping
Failure code [15K0MW] 1st clutch: Slipping
Failure code [15L0MW] 2nd clutch: Slipping
Failure code [15M0MW] 3rd clutch: Slipping
Failure code [15N0MW] 4th clutch: Slipping
Failure code [15SBL1] R clutch solenoid: Fill signal is ON when command current is OFF
Failure code [15SBMA] R clutch solenoid: Malfunction
Failure code [15SCL1] Hi clutch solenoid: Fill signal is ON when command current is OFF
Failure code [15SCMA] Hi clutch solenoid: Malfunction
Failure code [15SDL1] Lo clutch solenoid: Fill signal is ON when command current is OFF
Failure code [15SDMA] Lo clutch solenoid: Malfunction
Failure code [15SEL1] 1st clutch solenoid: Fill signal is ON when command current is OFF
Failure code [15SEMA] 1st clutch solenoid: Malfunction
Troubleshooting by failure code, Part 2
Failure code [15SFL1] 2nd clutch solenoid: Fill signal is ON when command current is OFF
Failure code [15SFMA] 2nd clutch solenoid: Malfunction
Failure code [15SGL1] 3rd clutch solenoid: Fill signal is ON when command current is OFF
Failure code [15SGMA] 3rd clutch solenoid: Malfunction
Failure code [15SHL1] 4th clutch solenoid: Fill signal is ON when command current is OFF
Failure code [15SHMA] 4th clutch solenoid: Malfunction
Failure code [15SJMA] Lockup clutch solenoid: Malfunction
Failure code [2F00KM] Parking brake: Mistake in operation or setting
Failure code [2G42ZG] Accumulator: Oil pressure reduction (Front)
Failure code [2G43ZG] Accumulator: Oil pressure reduction (Rear)
Failure code [989A00] Engine over run prevention command signal: Operating
Failure code [989D00] Rear section tipping over alarm: Alarm isactivated
Failure code [A570NX] Engine oil filter: Clogging
Failure code [AA10NX] Air cleaner element: Clogging
Failure code [AB00MA] Alternator: Malfunction
Failure code [B@BAZG] Abnormal lowering of engine oil pressure: Lowering of oil pressure
Failure code [B@BAZK] Engine oil: Level too low
Failure code [B@BCNS] Engine: Overheat
Failure code [B@BCZK] Lowering of radiator coolant: Lowering of level
Failure code [B@BFZK] Lowering of fuel level
Failure code [B@C6NS] Brake cooling oil: Overheating (Front)
Failure code [B@C7NS] Brake cooling oil: Overheating (Rear)
Failure code [B@CENS] Overheating of torque converter oil
Failure code [B@GAZK] Battery electrolyte level: Lowering of level
Failure code [B@JANS] Steering oil: Overheat
Troubleshooting by failure code, Part 3
Failure code [CA111] Engine controller (Left bank): Internal abnormality
Failure code [CB111] Engine controller (Right bank): Internal abnormality
Failure code [CA115] Abnormal engine Ne and Bkup speed sensors (At left bank): Abnormal speed sensor signal
Failure code [CB115] Abnormal engine Ne and Bkup speed sensors (At right bank): Abnormal speed sensor signal
Failure code [CA122] Charge pressure sensor too high (At left bank only): Excessively high voltage detected
Failure code [CA123] Charge pressure sensor too low (At left bank only): Excessively low voltage detected
Failure code [CA131] Throttle sensor high error
Failure code [CA132] Throttle sensor low error
Failure code [CA135] Oil pressure sensor too high (At left bank only): Excessively high voltage detected
Failure code [CA141] Oil pressure sensor too low (At left bank only): Excessively low voltage detected
Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected
Failure code [CA145] Coolant temperature sensor too low (At left bank only): Excessively low voltage detected
Failure code [CA153] Charge temperature sensor too high (At left bank only): Excessively high voltage detected
Failure code [CA154] Charge temperature sensor too low (At left bank only): Excessively low voltage detected
Failure code [CA187] Sensor power supply (2) abnormally low level (Left bank): Low voltage detection
Failure code [CB187] Sensor power supply (2) abnormally low level (Right bank): Low voltage detection
Failure code [CA212] Engine oil temperature sensor abnormally high level (Only left bank): High voltage detection
Failure code [CA213] Engine oil temperature sensor abnormally low level (Only left bank): Low voltage detection
Failure code [CA221] Atmospheric pressure sensor too high (At left bank only): Excessively high voltage detected
Failure code [CA222] Atmospheric pressure sensor too low (At left bank only): Excessively low voltage detected
Failure code [CA227] Sensor power source (2) too high (At left bank): Excessively high voltage detected
Failure code [CB227] Sensor power supply (2) abnormally high level (Right bank): High voltage detection
Failure code [CA234] Engine over speed (At left bank only): Excessively high speed
Failure code [CA238] Abnormal power source for Ne speed sensor (At left bank only): Excessively low voltage detected
Failure code [CB238] Abnormal power source for Ne speed sensor (At right bank only): Excessively low voltage detected
Failure code [CA263] Fuel temperature sensor too high (At left bank): Excessively high voltage detected
Failure code [CB263] Fuel temperature sensor too high (At right bank): Excessively high voltage detected
Failure code [CA265] Fuel temperature sensor abnormally low level (Left bank): Low voltage detection
Failure code [CB265] Fuel temperature sensor abnormally low level (Right bank): Low voltage detection
Failure code [CA271] PCV1 short circuit (Left bank): Short circuit
Failure code [CB271] PCV1 short circuit (Right bank): Short circuit
Failure code [CA272] PCV1 disconnection (Left bank): Disconnection
Failure code [CB272] PCV1 disconnection (Right bank): Disconnection
Failure code [CA273] PCV2 short circuit (Left bank): Short circuit
Failure code [CB273] PCV2 short circuit (Right bank): Short circuit
Failure code [CA274] PCV2 disconnection (Left bank): Disconnection
Failure code [CB274] PCV2 disconnection (Right bank): Disconnection
Troubleshooting by failure code, Part 4
Failure code [CA322] Injector No. 1 (L/B No.1) system disconnection or short circuit (At left bank): Disconnection, short circuit
Failure code [CA323] Injector No. 5 (L/B No.5) system disconnection or short circuit (At left bank): Disconnection, short circuit
Failure code [CA324] Injector No. 3 (L/B No.3) system disconnection or short circuit (At left bank): Disconnection, short circuit
Failure code [CA325] Injector No. 6 (L/B No.6) system disconnection or short circuit (At left bank): Disconnection, short circuit
Failure code [CA331] Injector No. 2 (L/B No.2) system disconnection or short circuit (At left bank): Disconnection, short circuit
Failure code [CA332] Injector No. 4 (L/B No.4) system disconnection or short circuit (At left bank): Disconnection, short circuit
Failure code [CA342] Engine controller data mismatch (Left bank): Mismatch
Failure code [CB342] Engine controller data mismatch (Right bank): Mismatch
Failure code [CA351] Abnormal injector drive circuit (At left bank): Abnormal circuit
Failure code [CB351] Injector drive circuit abnormality (Right bank): Circuit abnormality
Failure code [CA352] Sensor power supply (1) abnormally low level (Left bank): Low voltage detection
Failure code [CB352] Sensor power supply (1) abnormally low level (Right bank): Low voltage detection
Failure code [CA386] Sensor power supply (1) abnormally high level (Left bank): High voltage detection
Failure code [CB386] Sensor power supply (1) abnormally high level (Right bank): High voltage detection
Failure code [CA431] Trouble in idle validation switch
Failure code [CA432] Idle validation action error
Failure code [CA441] Power supply voltage abnormally low level (Left bank): Low voltage detection
Failure code [CB441] Power supply voltage abnormally low level (Right bank): Low voltage detection
Failure code [CA442] Power supply voltage abnormally high level (Left bank): High voltage detection
Failure code [CB442] Power supply voltage abnormally high level (Right bank): High voltage detection
Failure code [CA449] Common rail abnormally high pressure (2) (Left bank): Abnormally high pressure occurrence
Failure code [CB449] Common rail abnormally high pressure (2) (Right bank): Abnormally high pressure occurrence
Failure code [CA451] Common rail pressure sensor too high (At left bank): Excessively high voltage detected
Failure code [CB451] Common rail pressure sensor abnormally high level (Right bank): High voltage detection
Failure code [CA452] Common rail pressure sensor abnormally low level (Left bank): Abnormally low voltage detection
Failure code [CB452] Common rail pressure sensor abnormally low level (Right bank): Abnormally low voltage detection
Failure code [CA553] Common rail pressure too high (1) (At left bank): Excessively high pressure detected
Failure code [CB553] Common rail pressure too high (1) (At right bank): Excessively high pressure detected
Failure code [CA554] In-range error in common rail pressure sensor (At left bank): In-range error
Failure code [CB554] In-range error in common rail pressure sensor (At right bank): In-range error
Failure code [CA559] Loss of pressure feed from supply pump (1) (At left bank): Loss of pressure feed detected
Failure code [CB559] Loss of pressure feed from supply pump (1) (At right bank): Loss of pressure feed detected
Failure code [CA689] Abnormal engine Ne speed sensor (At left bank): Abnormal signal
Failure code [CB689] Abnormal engine Ne speed sensor (At right bank): Abnormal signal
Failure code [CA691] Intake air temperature sensor abnormally high level (Only left bank): High voltage detection
Failure code [CA692] Intake air temperature sensor abnormally low level (Only left bank): Low voltage detection
Failure code [CA731] Abnormal engine Bkup speed sensor phase (At left bank): Abnormal phase
Failure code [CB731] Abnormal engine Bkup speed sensor phase (At right bank): Abnormal phase
Troubleshooting by failure code, Part 5
Failure code [CA757] Loss of all engine controller data (At left bank): Loss of all data
Failure code [CB757] Loss of all engine controller data (At right bank): Loss of all data
Failure code [CA778] Abnormal engine Bkup speed sensor (At left bank): Abnormal Bkup signal
Failure code [CB778] Engine Bkup speed sensor abnormality (Right bank): Bkup signal error
Failure code [CA781] Inter-multicontroller communication error (Left bank): Communication error
Failure code [CB781] Inter-multicontroller communication error (Right bank): Communication error
Failure code [CA1257] Multicontroller distinction wiring harness key error (Left bank): Distinction error
Failure code [CB1257] Multicontroller distinction wiring harness key error (Right bank): Distinction error
Failure code [CB1548] Injector #7 (R/B #1) system disconnection/short circuit (Right bank): Disconnection/Short circuit
Failure code [CB1549] Injector #8 (R/B #2) system disconnection/short circuit (Right bank): Disconnection/Short circuit
Failure code [CB1551] Injector #10 (R/B #4) system disconnection/short circuit (Right bank): Disconnection/Short circuit
Failure code [CB1552] Injector #11 (R/B #5) system disconnection/short circuit (Right bank): Disconnection/Short circuit
Failure code [CB1553] Injector #12 (R/B #6) system disconnection/short circuit (Right bank): Disconnection/Short circuit
Failure code [CB1622] Injector #9 (R/B #3) system disconnection/short circuit (Right bank): Disconnection/Short circuit
Failure code [CA1633] KOMNET abnormality (Left bank): Communication error
Failure code [CA2185] Throttle sensor supply voltage high error
Failure code [CA2186] Throttle sensor power supply low error
Failure code [CA2249] Loss of pressure feed from supply pump (2) (At left bank): Loss of pressure feed detected
Failure code [CB2249] Loss of pressure feed from supply pump (2) (At right bank): Loss of pressure feed detected
Failure code [CA2555] Intake heater relay voltage low error (At left bank)
Failure code [CA2556] Intake heater relay voltage high error (At left bank)
Troubleshooting by failure code, Part 6
Failure code [D19HKB] Stop lamp relay output system: Short circuit
Failure code [DAF9KM] Wrong connection of connector
Failure code [DAFRKR] CAN communication error (Machine monitor):Communication error
Failure code [DAQ0KK] Transmission controller direct power supply:Lowering of source voltage
Failure code [DAQ0KT] Transmission controller nonvolatile memory:Abnormality in controller
Failure code [DAQ2KK] Transmission controller solenoid power source:Power source voltage too low
Failure code [DAQ9KQ] Transmission controller: Disagreement of model selection
Failure code [DAQRKR] Abnormality in CAN communication (Transmission)
Failure code [DAQRMA] Transmission controller option setting: Malfunction
Failure code [DB10KT] Retarder controller nonvolatile memory:Abnormality in controller
Failure code [DB12KK] Retarder controller solenoid power source:Power source system trouble
Failure code [DB13KK] Retarder controller battery direct power source:Power source voltage too low
Failure code [DB19KQ] Disagreement of model selection (Retarder controller)
Failure code [DB1RKR] CAN communication (retarder controller):Communication disabled
Failure code [DB1RMA] Disagreement of option setting (Retarder controller)
Failure code [DB2RKR] CAN communication (engine controller):Communication disabled
Failure code [dB2RKR] CAN communication (engine controller):Communication disabled
Failure code [DBBRKR] Abnormality in CAN communication (VHMS)
Failure code [DBC2KK] ABS controller solenoid power source: Power source system trouble
Failure code [DBC3KK] ABS controller battery direct power source:Power source voltage too low
Failure code [DBC9KQ] Disagreement of model selection (ABS controller)
Failure code [DBCRKR] Abnormality in CAN communication (ABS)
Failure code [DBCRMA] Disagreement of option setting (ABS controller)
Failure code [DDD7KX] Trouble in travel speed setting switch system:Out of input signal range
Failure code [DDD8KA] ARSC system switch system: Disconnection
Failure code [DDD8KB] ARSC system switch system: Short circuit
Failure code [DDD9KA] ABS system switch system: Disconnection
Failure code [DDD9KB] ABS system switch system: Short circuit
Failure code [DDDAKA] ASR system switch: Disconnection
Failure code [DDDAKB] ASR system switch: Short circuit
Failure code [DDP6L4] Service brake pressure switch trouble (Rear)
Failure code [DDTHKA] Hi clutch fill switch: Disconnection
Failure code [DDTJKA] Lo clutch fill switch: Disconnection
Failure code [DDTKKA] 1st clutch fill switch: Disconnection
Failure code [DDTLKA] 2nd clutch fill switch: Disconnection
Failure code [DDTMKA] 3rd clutch fill switch: Disconnection
Failure code [DDTNKA] R clutch fill switch: Disconnection
Failure code [DDTPKA] 4th clutch fill switch: Disconnection
Failure code [DF10KA] Gear shift lever: Disconnection
Failure code [DF10KB] Gear shift lever: Short circuit
Failure code [DGF1KX] Transmission oil temperature sensor: Out of input signal range
Failure code [DGR2KB] Trouble in retarder oil temperature sensor (rear wheel) system (Disconnection and short circuit)
Failure code [DGR2KZ] Trouble in retarder oil temperature sensor (rear wheel) system (Ground fault)
Failure code [DGR4KB] Trouble in retarder oil temperature sensor (front wheel) system (Disconnection and short circuit)
Failure code [DGR4KZ] Trouble in retarder oil temperature sensor (front wheel) system (Ground fault)
Failure code [DGR6KX] Steering oil temperature sensor: Input signal out of range
Failure code [DGT1KX] Torque converter oil temperature sensor: Out of input signal range
Troubleshooting by failure code, Part 7
Failure code [DHP4KY] Suspension pressure sensor system: Short circuit (Right front)
Failure code [DHP4KZ] Suspension pressure sensor system: Disconnection or ground fault (Right front)
Failure code [DHP5KY] Suspension pressure sensor system: Short circuit (Left front)
Failure code [DHP5KZ] Suspension pressure sensor system: Disconnection or ground fault (Left front)
Failure code [DHP6KA] Suspension pressure sensor system: Disconnection (Right rear)
Failure code [DHP6KX] Failure in suspension pressure sensor system trouble: Out of input signal range (Right rear)
Failure code [DHP6KY] Suspension pressure sensor system: Short circuit (Right rear)
Failure code [DHP6KZ] Suspension pressure sensor system: Disconnection or ground fault (Right rear)
Failure code [DHP7KA] Suspension pressure sensor system: Disconnection (Left rear)
Failure code [DHP7KX] Failure in suspension pressure sensor system trouble: Out of input signal range (Left rear)
Failure code [DHP7KY] Suspension pressure sensor system: Short circuit (Left rear)
Failure code [DHP7KZ] Suspension pressure sensor system: Disconnection or ground fault (Left rear)
Failure code [DHT5KX] Torque converter oil pressure sensor: Out of input signal range
Failure code [DHT5L6] Torque converter oil pressure sensor: Disagreement of run and stop condition with signal
Failure code [DHU2KX] Front accumulator oil pressure sensor: Out of input signal range
Failure code [DHU3KX] Rear accumulator oil pressure sensor: Out of input signal range
Failure code [DJF1KA] Fuel level sensor: Disconnection
Failure code [DK30KX] Steering angle potentiometer: Trouble (Disconnection)
Failure code [DK51L5] Trouble in retarder lever potentiometer and RVS
Failure code [DK52KX] Failure in hoist lever potentiometer 1: Out of input signal range
Failure code [DK53L8] Failure in hoist lever potentiometer 2: Disagreement of analog signal
Failure code [DK54KX] Body positioner sensor: Out of input signal range
Failure code [DKD0L6] Failure in steering angle speed sensor
Failure code [DKH0KX] Pitch angle sensor: Out of input signal range
Failure code [DKH1KX] Pitch angle sensor: Abnormality
Failure code [DLF1KA] Transmission input shaft speed sensor: Disconnection
Failure code [DLF1LC] Transmission input shaft speed sensor: Disagreement of revolution speed signal
Failure code [DLF2KA] Transmission intermediate shaft speed sensor: Disconnection
Failure code [DLF2LC] Transmission intermediate shaft speed sensor: Disagreement of revolution speed signal
Troubleshooting by failure code, Part 8
Failure code [DLF8KA] Wheel speed sensor: Disconnection (Right rear)
Failure code [DLF8L3] Wheel speed sensor: Disconnection (Right rear)
Failure code [DLF8LC] Wheel speed sensor: Trouble (Right rear)
Failure code [DLF8MA] Wheel speed sensor: Disconnection (Right rear)
Failure code [DLF9KA] Wheel speed sensor: Disconnection (Left rear)
Failure code [DLF9L3] Wheel speed sensor: Trouble (Left rear)
Failure code [DLF9LC] Wheel speed sensor: Trouble (Left rear)
Failure code [DLF9MA] Wheel speed sensor: Disconnection (Left rear)
Failure code [DLT3KA] Transmission output shaft speed sensor: Disconnection
Failure code [DLT3LC] Transmission output shaft speed sensor: Disagreement of revolution speed signal
Failure code [DLT4KA] Transmission output shaft speed sensor: Disconnection
Failure code [DLT4MA] Transmission output shaft speed sensor: Disconnection
Failure code [DV00KB] Buzzer output: Short circuit
Failure code [DW2AKA] Main pressure variable valve output: Disconnection
Failure code [DW2AKB] Main pressure variable valve output circuit: Ground fault
Failure code [DW2AKY] Main pressure variable valve output circuit: Hot short
Failure code [DW2AL1] Main pressure variable valve: Defective reset
Failure code [DW2ALH] Main pressure variable valve: Malfunction
Failure code [DW2BKA] Main oil level selector valve output: Disconnection
Failure code [DW2BKB] Main oil level selector valve output circuit:Ground fault
Failure code [DW2BKY] Main oil level selector valve output circuit: Hotshort
Failure code [DW2BL1] Main oil level selector valve: Defective reset
Failure code [DW2BLH] Main oil level selector valve: Malfunction
Failure code [DW2CKA] Transmission lubrication variable valve output: Disconnection
Failure code [DW2CKB] Transmission lubrication variable valve output circuit: Ground fault
Failure code [DW2CKY] Transmission lubrication variable valve output circuit: Hot short
Failure code [DW2CL1] Transmission lubrication variable valve: Defective reset
Failure code [DW2CLH] Transmission lubrication variable valve: Malfunction
Failure code [DW35KZ] Failure in output system of auto suspension solenoid 1: Disconnection or short circuit
Failure code [DW36KZ] Failure in output system of auto suspension solenoid 2: Disconnection or short circuit
Failure code [DW71KZ] Exhaust brake output system trouble (Disconection/Ground fault/Hot short)
Failure code [DW72KZ] Kick-out solenoid output system trouble: Disconnection or short circuit
Failure code [DW73KZ] Failure in hoist select valve output system: Disconnection or short circuit
Failure code [DW78KZ] Brake cooling valve (BCV) (rear wheel) output system trouble: Disconnection or short circuit
Failure code [DWNBK4] ASR shut-off valve: Trouble (Valve keeps operating)
Failure code [DWNBKA] ASR shut-off valve output circuit: Disconnection
Failure code [DWNBKB] ASR shut-off valve output circuit: Ground fault
Failure code [DWNBKY] ASR shut-off valve output circuit: Short circuit
Failure code [DWNBMA] ASR shut-off valve: Trouble (Valve does not operate)
Troubleshooting by failure code, Part 9
Failure code [DX11K4] Rear brake proportional pressure reducing solenoid valve: Out of control
Failure code [DX11KA] Rear brake proportional pressure reducing solenoid valve output circuit: Disconnection
Failure code [DX11KB] Rear brake proportional pressure reducing solenoid valve: Short circuit
Failure code [DX11KY] Rear brake proportional pressure reducing solenoid valve: Short circuit to power source line
Failure code [DX11MA] Rear brake proportional pressure reducing solenoid valve: Malfunction
Failure code [DX11MA] Rear brake proportional pressure reducing solenoid valve: Malfunction
Failure code [DX12K4] Front brake proportional pressure reducingsolenoid valve: Out of control
Failure code [DX12KA] Front brake proportional pressure reducing solenoid valve output circuit: Disconnection
Failure code [DX12KB] Front brake proportional pressure reducing solenoid valve: Short circuit
Failure code [DX12KY] Front brake proportional pressure reducing solenoid valve: Short circuit to power source line
Failure code [DX12MA] Front brake proportional pressure reducing solenoid valve: Malfunction
Failure code [DX13KA] Output circuit of hoist EPC valve: Disconnection
Failure code [DX13KB] Output circuit of hoist EPC valve: Short circuit
Failure code [DX13KY] Output circuit of hoist EPC valve: Short circuit with power source line
Failure code [DX17K4] ASR proportional pressure reducing solenoid valve (right): Trouble (Valve keeps operating)
Failure code [DX17KA] ASR proportional pressure reducing solenoid valve (right) output circuit: Disconnection
Failure code [DX17KB] ASR proportional pressure reducing solenoid valve (right) output circuit: Ground fault
Failure code [DX17KY] ASR proportional pressure reducing solenoid valve (right) output circuit: Short circuit
Failure code [DX17MA] ASR proportional pressure reducing solenoid valve (right): Trouble (Valve does not operate)
Failure code [DX18K4] ASR proportional pressure reducing solenoid valve (left): Trouble (Valve keeps operating)
Failure code [DX18KA] ASR proportional pressure reducing solenoid valve (left) output circuit: Disconnection
Failure code [DX18KB] ASR proportional pressure reducing solenoid valve (left) output circuit: Ground fault
Failure code [DX18KY] ASR proportional pressure reducing solenoid valve (left) output circuit: Short circuit
Failure code [DX18MA] ASR proportional pressure reducing solenoid valve (left): Trouble (Valve does not operate)
Troubleshooting by failure code, Part 10
Failure code [DXH1KA] Lockup clutch solenoid output circuit: Disconnection
Failure code [DXH1KB] Lock-up clutch solenoid output circuit: Short circuit
Failure code [DXH1KY] Lockup clutch solenoid output circuit: Short circuit to power source line
Failure code [DXH2KA] Hi clutch solenoid output circuit: Disconnection
Failure code [DXH2KB] Hi clutch solenoid output circuit: Short circuit
Failure code [DXH2KY] Hi clutch solenoid output circuit: Short circuit to power source line
Failure code [DXH3KA] Lo clutch solenoid output circuit: Disconnection
Failure code [DXH3KB] Lo clutch solenoid output circuit: Short circuit
Failure code [DXH3KY] Lo clutch solenoid output circuit: Short circuit in power source line
Failure code [DXH4KA] 1st clutch solenoid output circuit: Disconnection
Failure code [DXH4KB] 1st clutch solenoid output circuit: Short circuit
Failure code [DXH4KY] 1st clutch solenoid output circuit: Short circuit to power source line
Failure code [DXH5KA] 2nd clutch solenoid output circuit: Disconnection
Failure code [DXH5KB] 2nd clutch solenoid output circuit: Short circuit
Failure code [DXH5KY] 2nd clutch solenoid output circuit: Short circuit in power source line
Failure code [DXH6KA] 3rd clutch solenoid output circuit: Disconnection
Failure code [DXH6KB] 3rd clutch solenoid output circuit: Short circuit
Failure code [DXH6KY] 3rd clutch solenoid output circuit: Short circuit to power source line
Failure code [DXH7KA] R clutch solenoid output circuit: Disconnection
Failure code [DXH7KB] R clutch solenoid output circuit: Short circuit
Failure code [DXH7KY] R clutch solenoid output circuit: Short circuit to power source line
Failure code [DXHHKA] 4th clutch solenoid output circuit: Disconnection
Failure code [DXHHKB] 4th clutch solenoid output circuit: Short circuit
Failure code [DXHHKY] 4th clutch solenoid output circuit: Short circuit to power source line
Troubleshooting of electrical system (E-mode)
Before troubleshooting of electric system
Contents of troubleshooting table
E-1 Engine does not start
E-2 Automatic preheating does not operate
E-3 Machine monitor does not display all, when starting switch is turnedON
E-4 Machine monitor does not operate when starting switch is OFF
E-5 Alarm buzzer does not sound
E-6 Gauges of machine monitor, caution lamps or character displaysection do not display properly
E-7 A selection of the display in character display section cannot bechanged
E-8 Power mode selecting function does not operate properly
E-10 Seat belt caution lamp does not display properly
E-11 Turn signal lamp or turning lamp (hazard lamp) do not work properly
E-12 Night illumination (lighting) does not work properly
E-13 Emergency steering does not operate
E-14 Hoist lever does not operate normally
Troubleshooting of hydraulic and mechanical system (H-mode)
Contents of troubleshooting table
H-1 Machine does not start
H-2 Machine does not travel smoothly (hunting)
H-3 Lockup cannot be cancelled
H-4 Excessive shock when starting or shifting excessive
H-5 Transmission does not shift up
H-6 Machine lacks power or speed when traveling
H-7 Time lag is excessive when starting or shifting gear
H-8 Torque converter oil temperature is high
H-9 Torque converter oil pressure is low
H-10 Front brake is ineffective
H-11 Rear brake is ineffective
H-12 Steering wheel is heavy
H-13 Steering wheel does not work
H-14 Steering wheel vibrates
H-15 Dump body lifting speed is slow
H-16 Dump body does not work
H-17 Excessive hydraulic drift of dump body
Troubleshooting of engine (S-mode)
Method of using troubleshooting charts
S-1 Starting performance is poor
S-2 Engine does not start
S-3 Engine does not pick up smoothly
S-4 Engine stops during operations
S-5 Engine does not rotate smoothly
S-6 Engine lacks output (or lacks power)
S-7 Exhaust smoke is black (incomplete combustion)
S-8 Oil consumption is excessive (or exhaust smoke is blue)
S-9 Oil becomes contaminated quickly
S-10 Fuel consumption is excessive
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
S-12 Oil pressure drops
S-13 Oil level rises (Entry of coolant or fuel)
S-14 Coolant temperature becomes too high (overheating)
S-15 Abnormal noise is made
S-16 Vibration is excessive

50 Disassembly and assembly
General information on disassembly andassembly
How to read this manual
List of adhesives
Special tool list
Sketches of special tools
Engine and cooling system
Removal and installation of fuel supply pump
Removal and installation of cylinder head assembly
Removal and installation of radiator assembly
Removal and installation of engine assembly
Power train, Part 1
Removal and installation of front drive shaft
Removal and installation of torque converter and transmission assembly
Disconnection and connection of torque converter and transmission assembly
Disassembly and assembly of torque converter and PTO assemblies
Disassembly and assembly of transmission assembly
Power train, Part 2
Disassembly and assembly of differential assembly (Standard differential)
Disassembly and assembly of front brake assembly
Disassembly and assembly of rear brake assembly

90 Diagrams and drawings
Hydraulic diagrams and drawings
Power train hydraulic circuit diagram
Steering and hoist hydraulic circuit diagram
Brake hydraulic circuit diagram
Brake hydraulic circuit diagram (ASR specification)
Brake hydraulic circuit diagram (ABS specification)
Brake hydraulic circuit diagram (ASR and ABS specification)
Electrical diagrams and drawings
Electrical circuit diagram for outside cab (1/3)
Electrical circuit diagram for outside cab (2/3)
Electrical circuit diagram for outside cab (3/3)
Electrical circuit diagram for inside cab (1/3)
Electrical circuit diagram for inside cab (2/3)
Electrical circuit diagram for inside cab (3/3)
Electrical circuit diagram for VHMS
Electrical circuit diagram for ABS (Outside Cab)
Electrical circuit diagram for ABS (Inside Cab)
Electrical circuit diagram for ASR
Connectors table and arrangement drawing