HD785-7 SEN01274-15 Shop Manual-1206-1406

40 Troubleshooting SEN01944-02
Circuit diagram related
HD785-7 97
SEN01944-02 40 Troubleshooting
HD785-7 Dump truck

Form No. SEN01944-02
© 2010 KOMATSU
All Rights Reserved
Printed in Japan 11-10
98 HD785-7
SEN01945-02
DUMP TRUCK 1SHOP MANUAL
HD785-7
Machine model Serial number

HD785-7 7001 and up
40 Troubleshooting 1
Troubleshooting by failure code, Part 8
Failure code [DLF6KA] Disconnection in wheel speed sensor (Front right) ................................................... 4
Failure code [DLF6L3] Trouble in wheel speed sensor (Front right)............................................................... 6
Failure code [DLF7KA] Disconnection in wheel speed sensor (Front left)...................................................... 8
Failure code [DLF7L3] Trouble in wheel speed sensor (Front left) ............................................................... 10
Failure code [DLF8KA] Wheel speed sensor: Disconnection (Rear right) .................................................... 12
Failure code [DLF8L3] Wheel speed sensor: Disconnection (Rear right)..................................................... 14
Failure code [DLF8LC] Wheel speed sensor: Trouble (Rear right)............................................................... 16
Failure code [DLF8MA] Wheel speed sensor: Disconnection (Rear right) ................................................... 16
Failure code [DLF9KA] Wheel speed sensor: Disconnection (Rear left) ...................................................... 18
Failure code [DLF9L3] Wheel speed sensor: Trouble (Rear left).................................................................. 20
Failure code [DLF9LC] Wheel speed sensor: Trouble (Rear left) ................................................................. 22
Failure code [DLF9MA] Wheel speed sensor: Disconnection (Rear left)...................................................... 22
Failure code [DLT3KA] Transmission output shaft speed sensor: Disconnection......................................... 24
Failure code [DLT3LC] Transmission output shaft speed sensor:
Disagreement of revolution speed signal............................................................................................... 26
Failure code [DLT4KA] Transmission output shaft speed sensor: Disconnection......................................... 28
HD785-7 1
Failure code [DLT4MA] Transmission output shaft speed sensor: Disconnection ........................................ 30
Failure code [DUM7KY] Pre-lubrication operation lamp output abnormality: Hot short circuit...................... 32
Failure code [DUM7KZ] Pre-lubrication operation lamp output abnormality:
Disconnection or grounding fault ........................................................................................................... 34
Failure code [DV00KB] Buzzer output: Short circuit ..................................................................................... 36
Failure code [DW2AKA] Main pressure variable valve output: Disconnection.............................................. 38
Failure code [DW2AKB] Main pressure variable valve output circuit: Ground fault ...................................... 40
Failure code [DW2AKY] Main pressure variable valve output circuit: Hot short ........................................... 42
Failure code [DW2AL1] Main pressure variable valve: Defective reset ........................................................ 44
Failure code [DW2ALH] Main pressure variable valve: Malfunction ............................................................. 46
Failure code [DW2BKA] Main oil level selector valve output: Disconnection................................................ 47
Failure code [DW2BKB] Main oil level selector valve output circuit: Ground fault ........................................ 48
Failure code [DW2BKY] Main oil level selector valve output circuit: Hot short ............................................. 50
Failure code [DW2BL1] Main oil level selector valve: Defective reset .......................................................... 52
Failure code [DW2BLH] Main oil level selector valve: Malfunction ............................................................... 54
Failure code [DW2CKA] Transmission lubrication variable valve output: Disconnection.............................. 55
Failure code [DW2CKB] Transmission lubrication variable valve output circuit: Ground fault ...................... 56
Failure code [DW2CKY] Transmission lubrication variable valve output circuit: Hot short ........................... 58
Failure code [DW2CL1] Transmission lubrication variable valve: Defective reset ........................................ 60
Failure code [DW2CLH] Transmission lubrication variable valve: Malfunction ............................................. 62
Failure code [DW35KZ] Failure in output system of auto suspension solenoid 1:
Disconnection or short circuit................................................................................................................. 64
Failure code [DW36KZ] Failure in output system of auto suspension solenoid 2:
Failure code [DW71KZ] Exhaust brake output system trouble (Disconection/Ground fault/Hot short) ......... 68
Failure code [DW72KZ] Kick-out solenoid output system trouble: Disconnection or short circuit................. 70
Failure code [DW73KZ] Failure in hoist select valve output system: Disconnection or short circuit ............. 72
Failure code [DW78KZ] Brake cooling valve (BCV) (rear wheel) output system trouble:
Failure code [DWNBK4] ASR shut-off valve: Trouble (Valve keeps operating)............................................. 76
Failure code [DWNBKA] ASR shut-off valve output circuit: Disconnection ................................................... 78
Failure code [DWNBKB] ASR shut-off valve output circuit: Ground fault...................................................... 80
Failure code [DWNBKY] ASR shut-off valve output circuit: Short circuit ...................................................... 82
Failure code [DWNBMA] ASR shut-off valve: Trouble (Valve does not operate) .......................................... 82
Failure code [DWNDKZ] Trouble in ABS cut-off valve (Front) system .......................................................... 84
Failure code [DWNDMA] Defective ABS cut-off valve (Front) ...................................................................... 86
Failure code [DWNEKZ] Trouble in ABS cut-off valve (Rear) system........................................................... 88
Failure code [DWNEMA] Defective ABS cut-off valve (Rear) ....................................................................... 90
2 HD785-7
HD785-7 3
Failure code [DLF6KA] Disconnection in wheel speed sensor (Front

right) 1
Action code Failure code Disconnection in wheel speed sensor (Front right)
Trouble
E03 DLF6KA (ABS controller system)
Contents of • Defective harness wiring, defective speed sensor and the defective installation, etc. occurred and
trouble the pulse signal is not input to the signal circuit of wheel speed sensor (front right: FR).
Action of
controller • Stop ABS control.
Problem that
• ABS does not work.
appears on
machine • Ordinary brake operation can be carried out.
Related
information • Wheel speed sensor (FR) signal can be checked with monitoring (Code: 39707 (rpm)).
Cause Standard value in normal state/Remarks on troubleshooting

a Turn the starting switch OFF, disconnect WSFR and carry out
troubleshooting in this state.
Defective wheel speed
1
sensor (FR) WSFR (male: sensor side) Resistance
Between (1) – (2) 1,150 – 1,450 z
1) Turn the starting switch OFF.
2) Disconnect WSFR and ABS2.
Disconnection in wiring 3) Connect the T-branch and carry out troubleshooting in this state.
harness
2 (Disconnection in wiring or Between WSFR (female) (1) – ABS2 Resis-
Max. 1 z
defective contact in connec- (female) (40) tance
tor)
Between WSFR (female) (2) – ABS2 Resis-
Max. 1 z
(female) (29) tance
Possible causes
and standard a Turn the starting switch OFF, disconnect WSFR and carry out
value in normal Ground fault in wiring troubleshooting in this state.
state 3 harness
(Contact with ground circuit) Between WSFR (female) (1) and ground Resis-
Min. 1 Mz
tance
2) Disconnect connector ABS2 and WSFR.
Hot short in wiring harness 3) Connect T-branch to ABS2.
4 4) Turn the starting switch ON.
(Contact 24 V circuit)
Between ABS2 (40) – WSFR (female) (1)
Voltage Max. 1 V
and ground
2) Disconnect ABS2.
5 Defective ABS controller 3) Connect the T-branch and carry out troubleshooting in this state.
Between ABS2 (female) (40) – Resis-
1,150 – 1,450 z
(29) tance
4 HD785-7
HD785-7 5
Failure code [DLF6L3] Trouble in wheel speed sensor (Front right) 1

Action code Failure code Trouble in wheel speed sensor (Front right)
Trouble
E03 DLF6L3 (ABS controller system)
Contents of • Input signal (pulse signal) from the wheel speed sensor (front right: FR) to ABS controller is abnor-
trouble mal.
Action of
• Stop ABS control.
controller
Problem that
appears on
Related
• Wheel speed sensor (FR) signal can be checked with monitoring (Code: 39707 (rpm)).
information
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out troubleshooting for failure code [DLF6KA].
state
6 HD785-7
HD785-7 7
Failure code [DLF7KA] Disconnection in wheel speed sensor (Front left)1

Action code Failure code Disconnection in wheel speed sensor (Front left)
Trouble
E03 DLF7KA (ABS controller system)
Contents of • Defective harness wiring, defective speed sensor and the defective installation, etc. occurred and
trouble the pulse signal is not input to the signal circuit of wheel speed sensor (front left: FL).
Action of
controller • Stop ABS control.
Problem that
appears on
Related
information • Wheel speed sensor (FL) signal can be checked with monitoring (Code: 39706 (rpm)).

a Turn the starting switch OFF, disconnect WSFR and carry out
troubleshooting in this state.
1 Defective sensor
WSFR (male: sensor side) Resistance
Between (1) – (2) 1,150 – 1,450 z
2) Disconnect WSFL and ABS2.
Disconnection in wiring 3) Connect the T-branch and carry out troubleshooting in this state.
harness
2 (Disconnection in wiring or Between WSFR (female) (1) – ABS2 Resis-
Max. 1 z
defective contact in connec- (female) (30) tance
tor)
Between WSFL (female) (2) – ABS2 Resis-
Max. 1 z
(female) (29) tance
Possible causes
and standard a Turn the starting switch OFF, disconnect WSFL and carry out
value in normal Ground fault in wiring troubleshooting in this state.
state 3 harness
(Contact with ground circuit) Between WSFL (female) (1) and ground Resis-
Min. 1 Mz
tance
2) Disconnect connector ABS2 and WSFR.
Hot short in wiring harness 3) Connect T-branch to ABS2.
4 4) Turn the starting switch ON.
(Contact 24 V circuit)
Between ABS2 (30) – WSFL (female) (1)
Voltage Max. 1 V
and ground
2) Disconnect ABS2.
5 Defective ABS controller 3) Connect the T-branch and carry out troubleshooting in this state.
Between ABS2 (female) (30) – Resis-
1,150 – 1,450 z
(29) tance
8 HD785-7
HD785-7 9
Failure code [DLF7L3] Trouble in wheel speed sensor (Front left) 1

Action code Failure code Trouble in wheel speed sensor (Front left)
Trouble
Contents of • Input signal (pulse signal) from the wheel speed sensor (front left: FL) to ABS controller is abnor-
trouble mal.
Action of
• Stop ABS control.
controller
Problem that
appears on
Related
• Wheel speed sensor (FL) signal can be checked with monitoring (Code: 39706 (rpm)).
information

and standard
state
10 HD785-7
HD785-7 11
Failure code [DLF8KA] Wheel speed sensor: Disconnection (Rear

right) 1
Action code Failure code Wheel speed sensor: Disconnection (Rear right)
Trouble
E01 DLF8KA (Retarder controller system)
Contents of
• Wheel speed signal (pulse) is not input to retarder controller.
trouble
Action of
• Does not control ASR.
controller
Problem that
appears on • ASR is not controlled normally.
machine
• ABS controller inspects same trouble by failure code [DLF8MA].
a If ABS is installed and [DLF8MA] is not displayed, sensor and wiring harness out of cab are
judged normal.
a If ABS is installed and [DLF8MA] is displayed, perform following operations.
1) Turn starting switch OFF.
Related
2) Disconnect ABS7 connector.
information
3) Turn starting switch ON.
Check that failure code [DLF8KA] is displayed again (factors of ABS controller are eliminated)
and then carry out following troubleshooting.
• Input state from wheel speed sensor (right rear) can be checked with monitoring function (Code:
39709 (rpm)).

a Turn starting switch OFF and disconnect WSRR, then carry out
Defective wheel speed sen- troubleshooting without turning starting switch ON.
1
sor WSRR (Male: Sensor side) Resistance
Between (1) – (2) 1,750 z ± 10 %
Disconnection in wiring troubleshooting without turning starting switch ON.
Possible causes harness
Between WSRR (female) (1) – BRC2 Resis-
and standard 2 (Disconnection in wiring Max. 1 z
(female) (10) tance
value in normal or defective contact in
state connector) Between WSRR (female) (2) – BRC2 Resis-
Max. 1 z
(female) (39) tance
Grounding fault in wiring troubleshooting without turning starting switch ON.
3 harness
(Contact with ground circuit) Between WSRR (female) (1) – ground Resis-
Min. 1 Mz
tance
If causes 1 – 3 are not detected, retarder controller may be
4 Defective retarder controller defective. (Since trouble is in system, troubleshooting cannot
be carried out.)
12 HD785-7
HD785-7 13
Failure code [DLF8L3] Wheel speed sensor: Disconnection (Rear right)1

Trouble
Contents of
• Wheel speed signal (pulse) input to ABS controller is abnormal.
trouble
Action of
• Does not control ABS.
controller
Problem that
appears on • ABS is not controlled normally.
machine
• Retarder controller inspects same trouble by failure code [DLF8LC].
a If [DLF8L3] is not displayed, sensor and wiring harness out of cab are judged normal.
Related a If [DLF8LC] is displayed, disconnect BRC2 connector and check that [DLF8L3] is displayed
information again and then carry out following troubleshooting.
39709 (rpm)).

1
sor WSRR (Male: Sensor side) Resistance
Between (1) – (2) 1,750 z ± 10 %
a Turn starting switch OFF and disconnect BRC2, WSRR, ABS2
conector, then carry out troubleshooting without turning starting
Disconnection in wiring
harness switch ON.
Possible causes
and standard 2 (Disconnection in wiring Between WSRR (female) (1) – ABS2 Resis-
Max. 1 z
value in normal or defective contact in (female) (20) tance
state connector) Between WSRR (female) (2) – ABS2 Resis-
Max. 1 z
(female) (39) tance
3 harness
(Contact with ground circuit) Between WSRR (female) (1) – ground Resis-
Min. 1 Mz
tance
4 Defective retarder controller defective. (Since trouble is in system, troubleshooting cannot
be carried out.)
14 HD785-7
HD785-7 15
Failure code [DLF8LC] Wheel speed sensor: Trouble (Rear right) 1

Action code Failure code Wheel speed sensor: Trouble (Rear right)
Trouble
E01 DLF8LC (Retarder controller system)
Contents of
• Wheel speed signal (pulse) input to retarder controller is abnormal.
trouble
Action of
• Does not control retarder.
controller
Problem that
machine
• ABS controller inspects same trouble by failure code [DLF8L3].
a If ABS is installed and [DLF8L3] is not displayed, sensor and wiring harness out of cab are
judged normal.
Related
a If ABS is installed and [DLF8L3] is displayed, turn starting switch OFF and disconnect ABS7
information
connector. Check that failure code [DLF8LC] is displayed again.
39709 (rpm)).

and standard
state
Failure code [DLF8MA] Wheel speed sensor: Disconnection (Rear right)1

Trouble
E03 DLF8MA (ABS controller system)
Contents of
• Wheel speed signal (pulse) is not input to ABS controller.
trouble
Action of
controller
Problem that
machine
• Retarder controller inspects same trouble by failure code [DLF8KA].
a If [DLF8KA] is not displayed, sensor and wiring harness out of cab are judged normal.
Related a If [DLF8KA] is displayed, turn starting switch OFF and disconnect retarder controller connector
information BRC2 connector. Check that failure code [DLF8MA] is displayed again.
39709 (rpm)).

and standard
value in normal Carry out troubleshooting for failure code [DLF8L3].
state
16 HD785-7
HD785-7 17
Failure code [DLF9KA] Wheel speed sensor: Disconnection (Rear left) 1

Action code Failure code Wheel speed sensor: Disconnection (Rear left)
Trouble
E01 DLF9KA (Retarder controller system)
Contents of
• Wheel speed signal (pulse) is not input to retarder controller.
trouble
Action of
controller
Problem that
• ASR is not controlled normally.
appears on
• (ABS is not controlled normally.)
machine
• ABS controller inspects same trouble by failure code [DLF9MA].
a If ABS is installed and [DLF9MA] is not displayed, sensor and wiring harness out of cab are
judged normal.
a If ABS is installed and [DLF9MA] is displayed, perform following operations.
Related
2) Disconnect ABS7 connector.
information
Check that failure code [DLF9KA] is displayed again (factors of ABS controller are eliminated)
and then carry out following troubleshooting.
• Input state from wheel speed sensor (left rear) can be checked with monitoring function (Code:
39708 (rpm)).

a Turn starting switch OFF and disconnect WSRL, then carry out
troubleshooting without turning starting switch ON.
Defective wheel speed sen-
1
sor WSRL (Male: Sensor side) Resistance
Between (1) – (2) 1,750 z ± 10 %
Disconnection in wiring troubleshooting without turning starting switch ON.
Possible causes harness
Between WSRL (female) (1) – BRC2 Resis-
and standard 2 (Disconnection in wiring or Max. 1 z
(female) (20) tance
value in normal defective contact
state in connector) Between WSRL (female) (2) – BRC2 Resis-
Max. 1 z
(female) (39) tance
3 harness
(Contact with ground circuit) Between WSRL (female) (1) – ground Resis-
Min. 1 Mz
tance
4 Defective retarder controller defective. (Since trouble is in system, troubleshooting cannot be
carried out.)
18 HD785-7
HD785-7 19
Failure code [DLF9L3] Wheel speed sensor: Trouble (Rear left) 1

Action code Failure code Wheel speed sensor: Trouble (Rear left)
Trouble
Contents of
trouble
Action of
controller
Problem that
machine
• Retarder controller inspects same trouble by failure code [DLF9LC].
a If [DLF9LC] is not displayed, sensor and wiring harness out of cab are judged normal.
Related a If [DLF9LC] is displayed, disconnect BRC2 connector and check that [DLF9L3] is displayed
information again and then carry out following troubleshooting.
39708 (rpm)).

1
sor WSRL (Male: Sensor side) Resistance
Between (1) – (2) 1,750 z ± 10 %
a Turn starting switch OFF and disconnect BRC2, WSRL and
ABS2 connectors, then carry out troubleshooting without turn-
harness ing starting switch ON.
Possible causes
and standard 2 (Disconnection in wiring Between WSRL (female) (1) – ABS2 Resis-
Max. 1 z
value in normal or defective contact in (female) (11) tance
state connector) Between WSRL (female) (2) – ABS2 Resis-
Max. 1 z
(female) (39) tance
3 harness
(Contact with ground circuit) Between WSRL (female) (1) – ground Resis-
Min. 1 Mz
tance
carried out.)
20 HD785-7
HD785-7 21
Failure code [DLF9LC] Wheel speed sensor: Trouble (Rear left) 1

Action code Failure code Wheel speed sensor: Trouble (Rear left)
Trouble
E01 DLF9LC (Retarder controller system)
Contents of
trouble
Action of
controller
Problem that
machine
• ABS controller inspects same trouble by failure code [DLF9L3].
a If ABS is installed and [DLF9L3] is not displayed, sensor and wiring harness out of cab are
judged normal.
Related
a If ABS is installed and [DLF9L3] is displayed, turn starting switch OFF and disconnect ABS7
information
connector. Check that failure code [DLF9LC] is displayed again.
39708 (rpm)).

and standard
state
Failure code [DLF9MA] Wheel speed sensor: Disconnection (Rear left) 1

Action code Failure code Wheel speed sensor: Disconnection (Rear left)
Trouble
E03 DLF9MA (ABS controller system)
Contents of
• Wheel speed signal (pulse) is not input to ABS controller.
trouble
Action of
controller
Problem that
• ABS is not controlled normally.
appears on
• (Retarder is not controlled normally.)
machine
• Retarder controller inspects same trouble by failure code [DLF9KA].
a If [DLF9KA] is not displayed, sensor and wiring harness out of cab are judged normal.
Related a If [DLF9KA] is displayed, turn starting switch OFF and disconnect retarder controller connector
information BRC2 connector. Check that failure code [DLF9MA] is displayed again.
39708 (rpm)).

and standard
value in normal Carry out troubleshooting for failure code [DLF9L3].
state
22 HD785-7
HD785-7 23
Failure code [DLT3KA] Transmission output shaft speed sensor:

Disconnection 1
Action code Failure code Transmission output shaft speed sensor: Disconnection
Trouble
E03 DLT3KA (Transmission controller system)
Contents of • The signal circuit of the transmission output shaft speed sensor is disconnected and signals are not
trouble input.
• Keeps gear speed when trouble occurs.
Action of
• If gearshift lever is set in "N", gear is kept in neutral.
controller
• Turns lockup system OFF.
• Operator can move machine by following escape procedure.
1) Stop travel and set gearshift lever in "N" position.
2) Disconnect emergency escape connectors A1 (female) and A1 (male) and connect them to each
Problem that
other to set machine in emergency escape mode.
appears on
3) Operate gearshift lever and start machine again.
machine
a When operating gearshift lever, release accelerator pedal.
a Operate gearshift lever from N to D – L or from N to R.
a Machine is kept in emergency escape mode until starting switch is turned OFF.
Related
• This failure can be checked in the monitoring function (Code: 31400 (rpm)).
information

Press the sensor lightly against the revolution pickup gear, and
Wrong adjustment of
then return it by 1/2 – 1 turn.
1 transmission output shaft
a For details, see Testing and adjusting, "Adjustment of transmis-
speed sensor
sion speed sensor".
2) Disconnect connector CN5.
3) Connect T-adapter.
Defective transmission
2 Resis- 500 –
output shaft speed sensor Between CN5 (male) (1) – (2)
tance 1,000 z
Possible causes Resis-
Between CN5 (male) (1), (2) – ground Min. 1 Mz
and standard tance
value in normal 1) Turn the starting switch OFF.
state 2) Disconnect connectors BRC2, ATC2, CN5.
harness 3) Connect T-adapter to ATC2 (female) and CN5 (female).
3 (Disconnection in wiring or Wiring harness between ATC2 (female) (30) Resis-
Max. 1 z
defective contact in connec- – CN5 (female) (1) tance
tor) Wiring harness between ATC2 (female) (29) Resis-
Max. 1 z
– CN5 (female) (2) tance
2) Disconnect connectors BRC2, ATC2.
Defective transmission 3) Connect T-adapter to ATC2 (female).
4
controller
Resis- 500 –
Between ATC2 (female) (30) – (29)
tance 1,000 z
24 HD785-7
HD785-7 25
Failure code [DLT3LC] Transmission output shaft speed sensor:

Disagreement of revolution speed signal 1
Action code Failure code Transmission output shaft speed sensor: Disagreement of revolu-
Trouble tion speed signal
E01 DLT3LC (Retarder controller system)
• The speed calculated from the engine speed sensor signal, transmission input shaft speed sensor
Contents of
signal, and transmission intermediate shaft speed sensor signal is different from the signal speed of
trouble
the transmission output shaft speed sensor.
Action of • The controller keeps the current gear speed and turns the lockup operation OFF.
controller • If the shift lever is set in the "N" position, the controller keeps the gear in neutral.
Problem that
• The gear cannot be shifted.
appears on
machine • If the shift lever is set in the "N" position, the gear is set in neutral.
Related
• This failure can be checked in the monitoring function (Code: 31400 (rpm)).
information

1 Resis- 500 –
tance 1,000 z
Between CN5 (male) (1), (2) – chassis Resis-
Min. 1 Mz
ground tance
2) Disconnect connectors ATC2, BRC2, and CN5.
Grounding fault in wiring 3) Connect T-adapter.
2 harness
Possible causes
(Contact with ground circuit) Between ground and wiring harness Resis-
and standard between ATC2 (female) (30) – BRC2 Min. 1 Mz
value in normal tance
(female) (30) – CN5 (female) (1)
state
2) Disconnect connectors ATC2, BRC2, CN5.
Defective hot short in wiring 3) Connect T-adapter.
3 harness 4) Turn the starting switch ON.
(a contact with 24 V circuit) Wiring harness between ATC2 (female) (30)
– BRC2 (female) (30) – CN5 (female) (1) Voltage Max. 1 V
and chassis ground
2) Disconnect connector ATC2.
Defective transmission 3) Connect T-adapter.
4
controller
Resis- 500 –
Between ATC2 (female) (30) – (29)
tance 1,000 z
26 HD785-7
HD785-7 27
Failure code [DLT4KA] Transmission output shaft speed sensor:

Disconnection 1
Trouble
E01 DLT4KA (Retarder controller system)
Contents of • When ARSC, ASR, and auto-suspension are set, signal circuit of transmission output shaft speed
trouble sensor has disconnection and no signals are input.
• Turns output to ASR proportional solenoid OFF.
Action of • Turns output to auto-suspension solenoid OFF.
controller • When ARSC operates, brake is released gradually, then control is stopped until power is turned
OFF.
• ARSC control cannot be continued. (Even if ARSC switch ON with ARSC selection.)
• ASR control cannot be continued.
• Operator can move machine by following escape procedure.
Problem that 1) Stop travel and set gearshift lever in "N" position.
appears on 2) Disconnect emergency escape connectors A1 (female) and A1 (male) and connect them to each
machine other to set machine in emergency escape mode.
3) Operate gearshift lever and start machine again.
a When operating gearshift lever, release accelerator pedal.
a Operate gearshift lever from N to D – L or from N to R.
a Machine is kept in emergency escape mode until starting switch is turned OFF.
• Transmission output shaft speed can be checked with monitoring function (Code: 31400 (rpm)).
Related
Wheel speed can be also checked with monitoring function (Code: 39704 (rpm), 39705 (rpm)).
information
• Controller does not defect ground fault and hot short.

Press the sensor lightly against the revolution pickup gear, and
Wrong adjustment of
then return it by 1/2 - 1 turn.
1 transmission output shaft
speed sensor
sion speed sensor".
2) Connect T-adapter to connector CN5 (male).
Defective transmission Resis- 500 –
2 Between CN5 (male) (1) – (2)
output shaft speed sensor tance 1,000 z
Resis-
Possible causes Between CN5 (male) (1), (2) – ground Min. 1 Mz
tance
and standard
value in normal 1) Turn starting switch OFF.
state Disconnection in wiring 2) Disconnect connectors ATC2, BRC2, and CN5.
harness 3) Connect T-adapter to BRC2 (female) and CN5 (female).
3 (Disconnection in wiring or Wiring harness between BRC2 (female) (30) Resis-
Max. 1 z
defective contact in connec- – CN5 (female) (1) tance
tor) Wiring harness between BRC2 (female) (29) Resis-
Max. 1 z
2) Disconnect connectors BRC2 and ATC2.
4 Defective reterder controller 3) Connect T-adapter to BRC2 (female).
Resis- 500 –
Between BRC2 (female) (30) – (29)
tance 1,000 z
28 HD785-7
HD785-7 29
Failure code [DLT4MA] Transmission output shaft speed sensor:

Disconnection 1
Trouble
E03 DLT4MA (Reterder controller system)
Contents of • When ARSC, ASR, and auto-suspension are set, signal circuit of transmission output shaft speed
trouble sensor has disconnection and no signals are input.
• ASR control released.
• Turns output to ASR proportional solenoid OFF.
Action of
controller • Turns output to auto-suspension solenoid OFF.
• When ARSC operates, brake is released gradually, then control is stopped until power is turned
OFF.
Problem that
• ARSC control cannot be continued.
appears on
machine • ASR control cannot be continued.
• Transmission output shaft speed can be checked with monitoring function (Code: 31400 (rpm),
31403 (rpm)). Wheel speed can be also checked with monitoring function (Code: 39704 (rpm),
Related
39705 (rpm)).
information
• Controller does not defect ground fault and hot short.
• "Method for emergency escape procedure" refers to [DLT4KA]

2) Disconnect connectors ATC2, BRC2, CN5.
Disconnection in wiring 3) Connect T-adapter to connectors BRC2 (female) and CN5
harness (female).
1 (Disconnection in wiring or
Wiring harness between BRC2 (female) (30) Resis-
defective contact in connec- Max. 1 z
tor)
Wiring harness between BRC2 (female) (29) Resis-
Max. 1 z
2 Resis- 500 –
tance 1,000 z
Resis-
Between CN5 (male) (1), (2) – ground Min. 1 Mz
Possible causes tance
and standard Press the sensor lightly against the revolution pickup gear, and
value in normal Wrong adjustment of
then return it by 1/2 – 1 turn.
state 3 transmission output shaft
speed sensor
sion speed sensor".
2) Disconnect connectors ATC2, BRC2, PM5, and CN5.
Grounding fault in wiring 3) Connect T-adapter to connector BRC2 (female).
4 harness Between ground and wiring harness
(Contact with ground circuit) between BRC2 (female) (30) – ATC2 Resis-
Min. 1 Mz
(female) (30) – PM5 (female) (7) – CN5 tance
(female) (1)
2) Disconnect connectors BRC2, ATC2, PM5, and CN5.
3) Connect T-adapter to BRC2 (female).
Defective hot short in wiring 4) Turn the starting switch ON.
5 harness
(a contact with 24 V circuit) Between ground and wiring harness
between ATC2 (female) (30) – BRC2
Voltage Max. 1 V
(female) (30) – PM5 (female) (7) – CN5
(female) (1)
30 HD785-7

Possible causes 1) Turn the starting switch OFF.
and standard 2) Disconnect connector BRC2 and ATC2.
value in normal 6 Defective reterder controller 3) Connect T-adapter.
state Resis- 500 –
Between BRC2 (female) (30) – (29)
tance 1,000 z
HD785-7 31
Failure code [DUM7KY] Pre-lubrication operation lamp output

abnormality: Hot short circuit 1
Action code Failure code Pre-lubrication operation lamp output abnormality: Hot short circuit
Trouble
E01 DUM7KY (Pre-lubrication controller system)
Contents of • Pre-lubrication controller shows abnormality at operation lamp output: Hot short circuit is detected.
trouble (PRE5 (17) pin voltage: Min. 5.7 V)
Action of
• Pre-lubrication controller stops output to operation lamp.
controller
Problem that
appears on • Pre-lubrication operation lamp does not light up.
machine
Related • The output state of the pre-lubrication operation lamp can be checked with the monitoring code
information 40975, "D-00T-15" (1: ON, 0: OFF).

2) Disconnect PRE9 and PRE10, then carry out troubleshooting.
a Measure in diode range.
Defective pre-lubrication
1 Between connectors PRE10 (male) and
lamp Continuity Yes
PRE9 (female)
Between connectors PRE9 (female) and
Continuity None
PRE10 (male)
Possible causes
and standard
value in normal Between connectors PRE5 (female) (17) – Resis-
Min. 1 Mz
state (30) tance
Hot short circuit of wiring
2 harness (Contact with 1) Turn starting switch OFF.
power supply circuit) 2) Disconnect connector PRE10.
3) Connect T-branch to connector PRE5 (female).
4) Turn starting switch ON and carry out troubleshooting.
Between PRE5 (female) (17) and chassis
Voltage Max. 1 V
ground
If causes 1 – 2 are not detected, pre-lubrication controller may be
3 defective. (Since trouble is in system, troubleshooting cannot be car-
controller
ried out.)
Related electrical circuit diagram
a Prelube controller is the same as pre-lubrication controller.
32 HD785-7
HD785-7 33
Failure code [DUM7KZ] Pre-lubrication operation lamp output

abnormality: Disconnection or grounding fault 1
Action code Failure code Pre-lubrication operation lamp output abnormality: Disconnection or
Trouble grounding fault)
E01 DUM7KZ
(Pre-lubrication controller system)
• Pre-lubrication controller shows abnormality when the operation lamp does not output: Disconnec-
Contents of
tion and/or grounding fault is detected.
trouble
(PRE5 (17) pin voltage: Max. 5.7 V for 3 seconds)
Action of
• Pre-lubrication controller stops output to operation lamp.
controller
Problem that
appears on • Pre-lubrication operation lamp does not light up or remains lit.
machine
Related • The output state of the pre-lubrication operation lamp can be checked with the monitoring code
information 40975, "D-00T-15" (1: ON, 0: OFF).

a Measure in diode range.
1 Between connectors PRE10 (male) and
lamp Continuity Yes
PRE9 (female)
Between connectors PRE9 (male) and
Continuity None
PRE10 (male)
Disconnection in wiring 1) Turn starting switch OFF.
Possible causes harness (Disconnection or 2) Disconnect PRE5 and PRE9, then carry out troubleshooting.
2
and standard defective contact in Between connectors PRE5 (female) (17) – Resis-
Max. 1 z
value in normal connector) PRE9 (male) tance
state 1) Turn starting switch OFF.
2) Disconnect PRE5, PRE9 and PRE10, then carry out troubleshoot-
Grounding fault in wiring ing.
3 harness (Contact with Between PRE5 (female) (17) and chassis Resis-
Min. 1 Mz
ground circuit) ground tance
Resis-
Between PRE9 (female) and chassis ground Min. 1 Mz
tance
If causes 1 – 3 are not detected, pre-lubrication controller may be
4 defective. (Since trouble is in system, troubleshooting cannot be car-
controller
ried out.)
34 HD785-7
Related electrical circuit diagram
a Prelube controller is the same as pre-lubrication controller.
HD785-7 35
Failure code [DV00KB] Buzzer output: Short circuit 1

Action code Failure code Buzzer output: Short circuit
Trouble
E01 DV00KB (Machine monitor system)
Contents of
• When signal is output to buzzer circuit, abnormal current flows.
trouble
Action of • Keeps abnormality until starting switch is turned OFF.
machine monitor • Turns alarm buzzer output OFF.
Problem that
appears on • Alarm buzzer does not sound.
machine
Related • If buzzer sounds, BZ2 (2) is Sink output (Normal).
information • Controller cannot detect disconnection and ground fault of wiring harness.

1) Turn starting switch OFF, disconnect connector BZ2, and
remove buzzer.
1 Defective buzzer 2) Connect +24 V to BZ2 (male) (1) and connect GND to BZ2
(male) (2).
a If buzzer does not sound, buzzer is defective. (Replace)
Grounding fault in wiring a Turn starting switch OFF and disconnect BZ2, then carry out
harness troubleshooting without turning starting switch ON.
2
(Contact with ground circuit) Resis-
(Reference) Between DPC1 (male) (13) – ground Min. 1 Mz
tance
Possible causes 1) Turn starting switch OFF, disconnect DPC1 and BZ2, and insert
Hot short T-adapter in DPC1 (female).
and standard
3 (Contact with 24V circuit) in 2) Turn starting switch ON and carry out troubleshooting.
value in normal
wiring harness
state Between DPC1 (male) (13) – ground Voltage Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON. (When voltage in Cause 1 is
harness abnormal)
4 (Disconnection in wiring or Resis-
Between DPC1 (female) (13) – BZ2 (2) Max. 1 z
defective contact in tance
connector) (Reference) Resis-
Between BT2 (16) – BZ2 (1) Max. 1 z
tance
If causes 1 – 4 are not detected, machine monitor may be defec-
5 Defective machine monitor tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
36 HD785-7
HD785-7 37
Failure code [DW2AKA] Main pressure variable valve output:

Disconnection 1
Action code Failure code Main pressure variable valve output: Disconnection
Trouble
E01 DW2AKA (Transmission controller system)
Contents of
• When signal is output to main pressure variable valve solenoid circuit, no current flows.
trouble
Action of
• Stops outputting signal to main pressure variable valve solenoid circuit.
controller
Problem that
appears on • If the machine keeps traveling as it is, fuel consumption increases.
machine
• Output state to main pressure variable valve solenoid can be checked with monitoring function
Related (Code: 31643 (mA)).
information • Signal is not output to main pressure variable valve solenoid circuit until starting switch is turned
OFF once.

Defective main pressure without turning starting switch ON.
1 variable valve solenoid
CN27 (male) Resistance
(Internal disconnection)
Between (1) – (2) 5 – 15 z
Possible causes
and standard Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting
value in normal harness without turning starting switch ON. (When check result of Cause
state 2 (Disconnection in wiring 1 is normal)
or defective contact in Resis-
connector) Between ATC3 (female) (13) – (37) 5 – 15 z
tance
If causes 1 and 2 are not detected, transmission controller may be
3 defective. (Since trouble is in system, troubleshooting cannot be
controller
carried out.)
38 HD785-7
HD785-7 39
Failure code [DW2AKB] Main pressure variable valve output circuit:

Ground fault 1
Action code Failure code Main pressure variable valve output circuit: Ground fault
Trouble
E01 DW2AKB (Transmission controller system)
Contents of
• When signal is output to main pressure variable valve solenoid circuit, abnormal current flows.
trouble
Action of
controller
Problem that
machine
OFF once.

1 variable valve solenoid
Between (1) – (2) 5 – 15 z
a Turn starting switch OFF and disconnect CN27, then carry out
2 harness
(Contact with ground circuit) Between ATC3 (female) (37) – ground Resis-
Possible causes Min. 1 Mz
tance
and standard
value in normal a Turn starting switch OFF and disconnect CN27, then carry out
Short circuit in wiring troubleshooting without turning starting switch ON.
state
3 harness
(with another wiring harness) Wiring harness between ATC3 (female) (37) Resis-
Min. 1 Mz
– ATC3 (female) (pin other than 37) tance
a Turn starting switch OFF and insert T-adapter in ATC3, then turn
Hot short (Contact with 24 V starting switch ON and carry out troubleshooting.
4
circuit) in wiring harness
Between ATC3 (female) (37) – ground Voltage Max. 1 V
If causes 1 – 4 are not detected, transmission controller may be
controller
carried out.)
40 HD785-7
HD785-7 41
Failure code [DW2AKY] Main pressure variable valve output circuit: Hot
short 1
Action code Failure code Main pressure variable valve output circuit: Hot short
Trouble
E01 DW2AKY (Transmission controller system)
Contents of
• While signal is not output to main pressure variable valve solenoid circuit, abnormal current flows.
trouble
Action of
controller
Problem that
• Error [15*OMW] may be detected because of oil pressure reduction.
appears on
machine • The transmission clutch may be damaged during travel in F1, F2 or F3.
OFF once.

and standard
value in normal Carry out troubleshooting for failure code [DW2AKB].
state
42 HD785-7
HD785-7 43
Failure code [DW2AL1] Main pressure variable valve: Defective reset 1

Action code Failure code Main pressure variable valve: Defective reset
Trouble
E01 DW2AL1 (Transmission controller system)
Contents of • When outputting signal to main pressure variable valve solenoid circuit is stopped, response of
trouble main pressure switch is abnormal.
Action of
controller
Problem that
appears on
OFF once.

1 switch
Between (1) – (2) Max. 10 z
Defective main pressure Main pressure variable valve may have mechanical trouble.
2
variable valve Check it directly.
3 Defective hydraulic piping Hydraulic piping may be defective. Check it directly.
Possible causes Grounding fault in wiring troubleshooting without turning starting switch ON.
and standard 4 harness
value in normal Min. 1 Mz
tance
state
5 harness
Min. 1 Mz
– ATC (female) (pin other than 7) tance
6
controller
carried out.)
44 HD785-7
HD785-7 45
Failure code [DW2ALH] Main pressure variable valve: Malfunction 1

Action code Failure code Main pressure variable valve: Malfunction
Trouble
E01 DW2ALH (Transmission controller system)
Contents of • When signal is output to main pressure variable valve solenoid circuit, main pressure switch does
trouble not respond.
Action of
controller
Problem that
machine
OFF once.

and standard
value in normal Carry out troubleshooting for failure code [DW2AL1].
state
46 HD785-7
Failure code [DW2BKA] Main oil level selector valve output:

Disconnection 1
Action code Failure code Main oil level selector valve output: Disconnection
Trouble
E01 DW2BKA (Transmission controller system)
Contents of
• When signal is output to main oil level selector valve solenoid circuit, no current flows.
trouble
Action of
• Stops outputting signal to main oil level selector valve solenoid circuit.
controller
Problem that
machine
• Output state to main oil level selector valve solenoid can be checked with monitoring function
information • Signal is not output to main oil level selector valve solenoid circuit until starting switch is turned OFF
once.

Defective main oil level without turning starting switch ON.
1 selector valve solenoid
Possible causes Between (1) – (2) 5 – 15 z
value in normal harness without turning starting switch ON.
state 2 (Disconnection in wiring
Between ATC3 (female) (3) – (28) 5 – 15 z
connector) tance

controller
carried out.)
HD785-7 47
Failure code [DW2BKB] Main oil level selector valve output circuit:
Ground fault 1
Action code Failure code Main oil level selector valve output circuit: Ground fault
Trouble
E01 DW2BKB (Transmission controller system)
Contents of
• When signal is output to main oil level selector valve solenoid circuit, abnormal current flows.
trouble
Action of
controller
Problem that
machine
once.

1 selector valve solenoid
Between (1) – (2) 5 – 15 z
2 harness
tance
and standard
state
3 harness
Min. 1 Mz
4
controller
carried out.)
48 HD785-7
HD785-7 49
Failure code [DW2BKY] Main oil level selector valve output circuit: Hot
short 1
Action code Failure code Main oil level selector valve output circuit: Hot short
Trouble
E01 DW2BKY (Transmission controller system)
Contents of
• While signal is not output to main oil level selector valve solenoid circuit, abnormal current flows.
trouble
Action of
controller
Problem that
appears on
once.

and standard
value in normal Carry out troubleshooting for failure code [DW2BKB].
state
50 HD785-7
HD785-7 51
Failure code [DW2BL1] Main oil level selector valve: Defective reset 1
Action code Failure code Main oil level selector valve: Defective reset
Trouble
E01 DW2BL1 (Transmission controller system)
Contents of • When outputting signal to main oil level selector valve solenoid circuit is stopped, response of main
trouble oil level selector switch is abnormal.
Action of
controller
Problem that
appears on
once.

1 selector switch
Between (1) – (2) Max. 10 z
Defective main oil level Main oil level selector valve may have mechanical trouble.
2
selector valve Check it directly.
tance
state
5 harness
Min. 1 Mz
6
controller
carried out.)
52 HD785-7
HD785-7 53
Failure code [DW2BLH] Main oil level selector valve: Malfunction 1

Action code Failure code Main oil level selector valve: Malfunction
Trouble
E01 DW2BLH (Transmission controller system)
Contents of • When signal is output to main oil level selector valve solenoid circuit, main oil level selector switch
trouble does not respond.
Action of
controller
Problem that
machine
once.

and standard
value in normal Carry out troubleshooting for failure code [DW2BL1].
state
54 HD785-7
Failure code [DW2CKA] Transmission lubrication variable valve output:

Disconnection 1
Action code Failure code Transmission lubrication variable valve output: Disconnection
Trouble
E01 DW2CKA (Transmission controller system)
Contents of
• When signal is output to transmission lubrication variable valve solenoid circuit, no current flows.
trouble
Action of
• Stops outputting signal to transmission lubrication variable valve solenoid circuit.
controller
Problem that
machine
• Output state to transmission lubrication variable valve solenoid can be checked with monitoring
Related function (Code: 38001 (mA)).
information • Signal is not output to transmission lubrication variable valve solenoid circuit until starting switch is
turned OFF once.

Defective transmission lubri- without turning starting switch ON.
1 cation variable valve sole-
noid (Internal disconnection)
Between (1) – (2) 5 – 15 z
Possible causes
value in normal harness without turning starting switch ON. (When check result of Cause
state 2 (Disconnection in wiring 1 is normal)
connector) Between ATC3 (female) (23) – (38) 5 – 15 z
tance
controller
carried out.)
HD785-7 55
Failure code [DW2CKB] Transmission lubrication variable valve output

circuit: Ground fault 1
Action code Failure code Transmission lubrication variable valve output circuit: Ground fault
Trouble
E01 DW2CKB (Transmission controller system)
Contents of • When signal is output to transmission lubrication variable valve solenoid circuit, abnormal current
trouble flows.
Action of
controller
Problem that
machine
turned OFF once.

Defective transmission lubri- without turning starting switch ON.
1 cation variable valve sole-
noid (Internal disconnection)
Between (1) – (2) 5 – 15 z
2 harness
tance
and standard
state
3 harness
Min. 1 Mz
4
controller
carried out.)
56 HD785-7
HD785-7 57
Failure code [DW2CKY] Transmission lubrication variable valve output

circuit: Hot short 1
Action code Failure code Transmission lubrication variable valve output circuit: Hot short
Trouble
E01 DW2CKY (Transmission controller system)
Contents of • While signal is not output to transmission lubrication variable valve solenoid circuit, abnormal cur-
trouble rent flows.
Action of
controller
Problem that
appears on
turned OFF once.

and standard
value in normal Carry out troubleshooting for failure code [DW2CKB].
state
58 HD785-7
HD785-7 59
Failure code [DW2CL1] Transmission lubrication variable valve:

Defective reset 1
Action code Failure code Transmission lubrication variable valve: Defective reset
Trouble
E01 DW2CL1 (Transmission controller system)
Contents of • When outputting signal to transmission lubrication variable valve solenoid circuit is stopped,
trouble response of transmission lubrication variable valve pressure switch is abnormal.
Action of
controller
Problem that
appears on
turned OFF once.
Defective transmission lubri- a Prepare with starting switch OFF, then carry out troubleshooting
cation variable valve pres- without turning starting switch ON.
1
sure switch CN24 (male) Resistance
(Internal disconnection) Between (1) – (2) Max. 10 z
Defective transmission lubri- Transmission lubrication variable valve may have mechanical trou-
2
cation variable valve ble. Check it directly.
tance
state
5 harness
Min. 1 Mz
6
controller
carried out.)
60 HD785-7
HD785-7 61
Failure code [DW2CLH] Transmission lubrication variable valve:

Malfunction 1
Action code Failure code Transmission lubrication variable valve: Malfunction
Trouble
E01 DW2CLH (Transmission controller system)
Contents of • When signal is output to transmission lubrication variable valve solenoid circuit, transmission lubri-
trouble cation variable valve pressure switch does not respond.
Action of
controller
Problem that
machine
turned OFF once.

and standard
value in normal Carry out troubleshooting for failure code [DW2CL1].
state
62 HD785-7
HD785-7 63
Failure code [DW35KZ] Failure in output system of auto suspension

solenoid 1: Disconnection or short circuit 1
Action code Failure code Failure in output system of auto suspension solenoid 1: Disconnec-
Trouble tion or short circuit
E01 DW35KZ (Retarder controller system)
Contents of • When the output to the auto suspension solenoid 1 circuit is ON, a too large current flows or any
trouble current does not flow. Or, some current is flowing while the output is OFF.
Action of
• The controller turns the output to auto suspension solenoid 1 and 2 OFF.
controller
Problem that
appears on • The auto suspension system does not operate.
machine
Related
information

2) Disconnect connector S04.
3) Insert T-adapter.
Defective auto suspension
1 Resis-
solenoid 1 Between S04 (female) (1) – (2) 15 – 35 z
tance
Resis-
Between S04 (female) (1), (2) – ground Min. 1 Mz
tance
Disconnection in wiring 2) Disconnect connectors BRC3 and S04.
harness 3) Connect T-adapter.
Possible causes 2 (Disconnection in wiring or Wiring harness between BRC3 (female) (7) Resis-
Max. 1 z
and standard defective contact in connec- – S04 (female) (1) tance
value in normal tor) Wiring harness between BRC3 (female) (3) Resis-
state Max. 1 z
– S04 (female) (2) tance
2) Disconnect BRC3 and S04.
Hot short in wiring harness 3) Connect T-adapter to BRC3 (female).
3 4) Turn starting switch ON.
(Contact with 24 V circuit)
Wiring harness between BRC3 (female) (7)
Voltage Max. 1 V
– S04 (female) (1) and chassis ground
2) Disconnect connector BRC3.
4 Defective retarder controller 3) Insert T-adapter.
Resis-
Between BRC3 (female) (7) – ground 15 – 35 z
tance
64 HD785-7
HD785-7 65
Failure code [DW36KZ] Failure in output system of auto suspension

solenoid 2: Disconnection or short circuit 1
Action code Failure code Failure in output system of auto suspension solenoid 2: Disconnec-
Trouble tion or short circuit
Contents of • When the output to the auto suspension solenoid 2 circuit is ON, a too large current flows or any
trouble current does not flow. Or, some current is flowing while the output is OFF.
Action of
• The controller turns the output to auto suspension solenoid 1 and 2 OFF.
controller
Problem that
appears on • The auto suspension system does not operate.
machine
Related
information

2) Disconnect connector S05.
Defective auto suspension
1 Resis-
solenoid 2 Between S05 (female) (1) – (2) 15 – 35 z
tance
Resis-
Between S05 (female) (1), (2) – ground Min. 1 Mz
tance
Disconnection in wiring 2) Disconnect connectors BRC3 and S05.
Possible causes 2 (Disconnection in wiring or Wiring harness between BRC3 (female) (37) Resis-
Max. 1 z
and standard defective contact in connec- – S05 (female) (1) tance
value in normal tor) Wiring harness between BRC3 (female) (3) Resis-
state Max. 1 z
– S05 (female) (2) tance
2) Disconnect BRC3 and S05.
3 4) Turn starting switch ON.
(Contact with 24 V circuit)
Voltage Max. 1 V
– S05 (female) (1) and chassis ground
Resis-
Between BRC3 (female) (37) – ground 15 – 20 z
tance
66 HD785-7
HD785-7 67
Failure code [DW71KZ] Exhaust brake output system trouble

(Disconection/Ground fault/Hot short) 1
Action code Failure code Exhaust brake output system trouble (Disconection/Ground fault/
Trouble Hot short)
Contents of
• Disconection/Ground fault/Hot short of Exhaust brake solenoid.
trouble
• Ground fault at the time of the detection,turn off exhaust brake and do not return normally unless
Action of
turn off a start switch once.
controller
• Disconection/Hot short fault at the time of the detection,continue control of exhaust brake.
Problem that
appears on • Exhaust brake do not operate normally.
machine
Related • Condition of exhaust brake can be checked with monitoring function.
information (Code:3 5900 exhaust brake OFF[0],ON[1])"

Defective exhaust brake without turning starting switch ON.
1
solenoid EXSOL(male) Resistance
Between (1) – (2) 15 – 30 z
Disconnection in wiring without turning starting switch ON.
harness
Between wiring harness BRC3 (female) (13) Resis-
2 (Disconnection in wiring Max. 1 z
– EXSOL(female) (2) tance
or defective contact in
connector) Between wiring harness BRC3 (female) (38) Resis-
Max. 1 z
– EXSOL(female) (1) tance
Possible causes Grounding fault in wiring without turning starting switch ON.
and standard 3 harness Between ground and wiring harness
value in normal (Contact with ground circuit) between BRC3 (female) (38) – EXSOL Resis-
Min. 1 Mz
state tance
(female) (1)
2) Disconnect connectors BRC3 and EXSOL.
4 (Contact with power source 4) Turn the starting switch ON.
wiring harness) Between ground and wiring harness
between BRC3 (female) (38) – EXSOL Voltage Max. 1 V
(female) (1)
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
5 Defective retarder controller Between BRC3 (38) – (13) Voltage
Exhaust brake not operating Max. 1 V
Exhaust brake operating 20 – 30 V
68 HD785-7
HD785-7 69
Failure code [DW72KZ] Kick-out solenoid output system trouble:

Disconnection or short circuit 1
Action code Failure code Kick-out solenoid output system trouble: Disconnection or short
Trouble circuit
Contents of • When signal is output to hoist lever kick-out solenoid circuit, large current flows or no current flows
trouble or when signal is not output, some current flows.
Action of
• Turns output to hoist lever kick-out solenoid OFF.
controller
Problem that
appears on • Hoist lever is not locked by detent.
machine
• This phenomenon also occurs when signals from body potentiometer and sensor are abnormal.
Related
(See failure code DK54KX.)
information
• When kick-out solenoid needs to be replaced, hoist lever must be replaced.

Disconnection in wiring 2) Disconnect connector BRC3 and LK0.
1 (Disconnection in wiring or Wiring harness between LK0 (female) (2) – Resis-
Max. 1 z
defective contact in connec- ground tance
Max. 1 z
– LK0 (female) (1) tance
2) Disconnect connector BRC3 and LK0.
Defective hot short in wiring 3) Connect T-adapter to BRC3 (female).
2 harness 4) Turn starting switch ON.
Possible causes (a contact with 24 V circuit)
and standard Wiring harness between BRC3 (female) (27)
Voltage Max. 1 V
value in normal – LK0 (female) (1) and chassis ground
state 1) Turn the starting switch OFF.
2) Disconnect connector LK0.
Defective hoist lever kick-out
3 Resis- 39 z ±
solenoid Between LK0 (male) (1) – (2)
tance 5%
Resis-
Between LK0 (male) (1) and (2) – ground Min. 1 Mz
tance
4 Defective retarder controller 3) Connect T-adapter.
Resis- 39 z ±
Between BRC3 (female) (27) – ground
tance 5%
70 HD785-7
HD785-7 71
Failure code [DW73KZ] Failure in hoist select valve output system:

Disconnection or short circuit 1
Action code Failure code Failure in hoist select valve output system: Disconnection or short
Trouble circuit
Contents of • When the output to the hoist lever select valve solenoid circuit is ON, a too large current flows or
trouble any current does not flow. Or, some current is flowing while the output is OFF.
Action of • The controller turns the output to the hoist lever select valve solenoid OFF.
controller • The controller turns the output to the hoist lever EPC valve solenoid OFF.
Problem that
appears on • Body does not operate.
machine
Related
information

Disconnection in wiring 2) Disconnect connectors BRC3 and HSOL.
1 (Disconnection in wiring or Wiring harness between BRC3 (female) (3) Resis-
Max. 1 z
defective contact in connec- – HSOL (female) (2) tance
Max. 1 z
– HSOL (female) (1) tance
2) Disconnect connectors BRC3 and HSOL.
Defective hot short in wiring 3) Connect T-adapter to BRC3 (female).
2 harness 4) Turn the starting switch ON.
Possible causes (a contact with 24 V circuit) Between ground and wiring harness
and standard
between BRC3 (female) (17) – HSOL Voltage Max. 1 V
value in normal
(female) (1)
state
2) Disconnect connector HSOL.
Defective hoist lever select
3 Resis-
valve solenoid Between HSOL (male) (1) – (2) 15 – 35 z
tance
Resis-
Between HSOL (male) (1), (2) – ground Min. 1 Mz
tance
2) Disconnect connector HSOL.
Resis-
Between BRC3 (female) (17) – (13) 15 – 35 z
tance
72 HD785-7
HD785-7 73
Failure code [DW78KZ] Brake cooling valve (BCV) (rear wheel) output
system trouble: Disconnection or short circuit 1
Action code Failure code Brake cooling valve (BCV) (rear wheel) output system trouble:
Trouble Disconnection or short circuit
Contents of • Since no current flows or overcurrent flows in BCV relay primary side, BCV relay cannot be turned
trouble ON/OFF. Accordingly, BCV solenoid cannot be driven.
Action of • Stops supplying current when BCV circuit is disconnected.
controller • Turns output to BCV relay (R14) primary side OFF.
Problem that
appears on • Since retarder is not cooled, it may overheat.
machine
Related
• For troubleshooting for BCV relay (R14) secondary side, see [B@C7NS].
information

a Turn starting switch OFF and disconnect R14 (BCV relay), then
carry out troubleshooting without turning starting switch ON.
1 Defective R14 (BCV relay) R14
Resistance
(female: Wiring harness side)
Between (1) – (2) 100 – 500 z
a Turn starting switch OFF and disconnect R14 (BCV relay), then
Grounding fault in wiring carry out troubleshooting without turning starting switch ON.
2 harness
(Contact with ground circuit) Between R14 (female) (1) – ground Min. 1 Mz
and standard tance
value in normal
a Turn starting switch OFF and disconnect R14 (BCV relay) and
state
Disconnection in wiring BRC3, then carry out troubleshooting without turning starting
harness switch ON.
3 (Disconnection in wiring Between BRC3 (female) (18) – R14 Resis-
Max. 1 z
or defective contact in (female) (1) tance
connector) Resis-
Between ER1 (ground) – R14 (female) (2) Max. 1 z
tance
If causes 1 – 4 are not detected, retarder controller may be defec-
4 Defective retarder controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
74 HD785-7
HD785-7 75
Failure code [DWNBK4] ASR shut-off valve: Trouble (Valve keeps

operating) 1
Action code Failure code ASR shut-off valve: Trouble (Valve keeps operating)
Trouble
E01 DWNBK4 (Retarder controller system)
Contents of
• ASR pressure sensor does not respond to shut-off valve OFF command of retarder controller.
trouble
Action of
• Stops controlling ASR.
controller
Problem that
machine
• ASR pressure sensor is turned OFF when pressure is 0.3 MPa {3 kg/cm²} or less. (In range of 0.3
Related
MPa {3 kg/cm²} – 0.7 MPa {7 kg/cm²}, operation of sensor is unstable because of hysteresis.)
information
• If ASR shut-off valve has electrical trouble, code [DWNBKA], [DWNBKB] or [DWNBKY] is output.

a ASR shut-off valve may have mechanical trouble. Check it
directly.
1 Defective ASR shut-off valve 1) Turn starting switch ON.
2) Turn ASR switch ON/OFF.
Operating sound of ASR shut-off valve solenoid is heard.
2) Disconnect ASR7.
3) Prepare and turn starting switch ON.
Defective ASR pressure sen- 4) Turn ASR switch ON and OFF and carry out troubleshooting.
2
sor ASR7 (male) (1) – (2) Resistance
Possible causes Turn ASR switch OFF Min. 1 Mz

and standard Turn ASR switch ON Max. 1 z
value in normal a Turn starting switch OFF and disconnect ASR7 and BRC3, then
state Disconnection in wiring carry out troubleshooting without turning starting switch ON.
harness
Between ASR7 (female) (1) – BRC3 Resis-
3 (Disconnection in wiring or Max. 1 z
(female) (30) tance
defective contact in connec-
tor) Between ASR7 (female) (2) – BRC3 Resis-
Max. 1 z
(female) (21) tance
a Turn starting switch OFF and disconnect ASR7, then carry out
4 harness
(Contact with ground circuit) Between ASR7 (female) (1) – ground Resis-
Min. 1 Mz
tance
out.)
76 HD785-7
HD785-7 77
Failure code [DWNBKA] ASR shut-off valve output circuit:

Disconnection 1
Action code Failure code ASR shut-off valve output circuit: Disconnection
Trouble
E01 DWNBKA (Retarder controller system)
Contents of
• When signal is output to ASR shut-off valve solenoid circuit, no current flows.
trouble
Action of
controller
Problem that
machine
Related
• Signal is not output to ASR shut-off valve solenoid circuit until starting switch is turned OFF once.
information

Defective ASR shut-off valve without turning starting switch ON.
1 solenoid
ASR2 (male) Resistance
Between (1) – (2) 5 – 15 z
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
and standard Disconnection in wiring without turning starting switch ON. (When check result of Cause
value in normal harness 1 is normal)
state 2 (Disconnection in wiring Resis-
Between J04 (male) (42) – (43) 5 – 15 z
or defective contact in tance
connector) Resis-
tance
If causes 1 and 2 are not detected, retarder controller may be
carried out.)
78 HD785-7
HD785-7 79
Failure code [DWNBKB] ASR shut-off valve output circuit: Ground fault1
Action code Failure code ASR shut-off valve output circuit: Ground fault
Trouble
E01 DWNBKB (Retarder controller system)
Contents of
• When signal is output to ASR shut-off valve solenoid circuit, abnormal current flows.
trouble
Action of
controller
Problem that
machine
Related
information

Defective ASR shut-off valve troubleshooting without turning starting switch ON.
1 solenoid
ASR2 (male) Resistance
(Internal short circuit)
Between (1) – (2) 5 – 15 z
a Turn starting switch OFF and disconnect BRC3 and ASR2, then
2 harness
(Contact with ground circuit) Between BRC3 (female) (15) – ground Resis-
tance
and standard
value in normal a Turn starting switch OFF and disconnect BRC3 and ASR2, then
Short circuit in wiring carry out troubleshooting without turning starting switch ON.
state
3 harness
(with another wiring harness) Wiring harness between BRC3 (female) Resis-
Min. 1 Mz
(15) – BRC3 (female) (pin other than (15)) tance
a Turn starting switch OFF and insert T-adapter in BRC3, then
Hot short (Contact with 24 V turn starting switch ON and carry out troubleshooting.
4
Between BRC3 (female) (15) – ground Voltage Max. 1 V
out.)
80 HD785-7
HD785-7 81
Failure code [DWNBKY] ASR shut-off valve output circuit: Short circuit1
Action code Failure code ASR shut-off valve output circuit: Short circuit
Trouble
E01 DWNBKY (Retarder controller system)
Contents of
• When signal is output to ASR shut-off valve solenoid circuit, abnormal current flows.
trouble
Action of
controller
Problem that
machine
Related
information

and standard
value in normal Carry out troubleshooting for failure code [DWNBKB].
state
Failure code [DWNBMA] ASR shut-off valve: Trouble (Valve does not
operate) 1
Action code Failure code ASR shut-off valve: Trouble (Valve does not operate)
Trouble
E01 DWNBMA (Retarder controller system)
Contents of
• Sensor does not respond to shut-off valve ON command of retarder controller.
trouble
Action of
controller
Problem that
• Retarder is not controlled normally.
appears on
machine • ASR is not controlled normally.
• ASR pressure sensor is turned ON when pressure is 0.7 MPa {7 kg/cm²} or above. (In range of 0.3
Related
MPa {3 kg/cm²} – 0.7 MPa {7 kg/cm²}, operation of sensor is unstable because of hysteresis.)
information
• If ASR shut-off valve has electrical trouble, code [DWNBKA], [DWNBKB] or [DWNBKY] is output.

and standard
value in normal Carry out troubleshooting for failure code [DWNBK4].
state
82 HD785-7
HD785-7 83
Failure code [DWNDKZ] Trouble in ABS cut-off valve (Front) system 1

Action code Failure code Trouble in ABS cut-off valve (Front) system
Trouble
E03 DWNDKZ (ABS controller system)
• Large amount of current flows or the current does not flow when signal is output to the primary cir-
Contents of
cuit of ABS cut-off valve relay (Front) (CUTF).
trouble
• The current flows when ABS cut-off valve relay (Front) (CUTF) is turned OFF.
Action of • Stop outputting to ABS cut-off valve relay (Front)(CUTF).
controller (Stop ABS control.)
Problem that
appears on
• No signal is output to ABS cut-off valve relay (Front) (CUTF) until starting switch is turned OFF.
Related
information • ABS controller is carrying out troubleshooting for the primary coil side of the ABS cut-off valve relay
(Front) (CUTF).

1) Turn the starting switch OFF and remove the relay cover.
2) Replace R11 (horn relay) and CUTF relay.
3) Turn the starting switch ON (without starting the engine).
1 Defective relay (CUTF) 4) Sound the horn.
The horn sounds. Relay (CUTF) is normal.
Abnormal relay (CUTF)
The horn does not sound.
(Replace).
2) Disconnect ABS3 and CUTF relay.
Disconnection in wiring 3) Connect T-branch to ABS3 (female) and CUTF (female) and
harness carry out troubleshooting in this state.
Resis-
defective contact in connec- Between ABS3 (female) (8) – CUTF (1) Max. 1 z
tance
tor)
Resis-
Between ABS3 (female) (21) – CUTF (2) Max. 1 z
and standard 1) Turn the starting switch OFF.
value in normal 2) Disconnect ABS3 and CUTF relay.
state Ground fault in wiring 3) Connect T-branch to ABS3 (female) or CUTF (female) and
3 harness carry out troubleshooting in this state.
(Contact with ground circuit)
Between ABS3 (female) (8) – ABS3 Resis-
Min. 1 Mz
(female) (21) tance
2) Disconnect CVF.
Hot short in wiring harness 3) Connect T-branch.
4
(Contact 24 V circuit) 4) Turn the starting switch ON.
Between CVF (1) – CVF (2) Voltage Max. 1 V
2) Disconnect ABS3 and CUTF.
3) Connect T-branch to ABS3 (female) and CUTF (female).
5 Defective ABS controller 4) Turn the starting switch ON (without starting the engine).
5) Turn ABS switch ON and OFF.
Between ABS3 (female) (8) and ABS3 24 V/0 V
Voltage
(female) (21) change
84 HD785-7
HD785-7 85
Failure code [DWNDMA] Defective ABS cut-off valve (Front) 1

Action code Failure code Defective ABS cut-off valve (Front)
Trouble
E03 DWNDMA (ABS controller system)
Contents of • Command to ABS cut-off valve solenoid (Front) does not match response from the ABS cut-off
trouble valve solenoid switch (Front)
Action of • Stop outputting to ABS cut-off valve relay (Front) (CUTF).
Problem that
appears on
• Ordinary brake operation can be carried out.
machine
• ABS cut-off valve solenoid (front) is turned ON and OFF by turning the ABS cut-off valve relay
(Front) (CUTF) ON and OFF.
Related
• No signal is output to ABS cut-off valve relay (Front) (CUTF) until starting switch is turned OFF.
information
• ABS controller is carrying out troubleshooting for the primary coil side of the ABS cut-off valve relay
(Front) (CUTF) with [DWNDKZ].

2) Replace R11 (horn relay) and CUTF relay.
1 Defective relay (CUTF) 4) Sound the horn.
The horn sounds. Relay (CUTF) is normal.
Abnormal relay (CUTF)
(Replace).
Defective solenoid (Internal 2) Disconnect connector CVF and carry out troubleshooting in this
2 disconnection) of ABS cut-off state.
valve (Front) CVF (male) Resistance
Between (1) – (2) 10 – 30 z
2) Disconnect connector CVSF.
3) Connect T-branch to connector CVSF and extend the wiring.
4) Start engine.
Possible causes Defective ABS cut-off sole- 5) Turn ABS switch ON and OFF.
3
and standard noid switch (Front)
Resis-
value in normal OFF: between CVSF (1) – (2) Min. 1 Mz
tance
state
Resis-
ON: between CVSF (1) – (2) Max. 1 z
tance
2) Disconnect CUTF relay, connectors ABS1, ABS3, CVF and
CVSF.
3) Connect T-branch to ABS1 (female), ABS3 (female), CUTF
(female) and CVSF (female) and carry out troubleshooting in
this state.
Disconnection in wiring Resis-
Between ABS3 (female) (2) – CUTF (5) Max. 1 z
harness tance
defective contact in connec- Between CVF (female) (1) – CUTF (3) Max. 1 z
tance
tor)
Resis-
Between CVF (female) (2) – chassis ground Max. 1 z
tance
Resis-
Between ABS1 (female) (23) – CVSF (1) Max. 1 z
tance
Resis-
Between ABS3 (female) (21) – CVSF (2) Max. 1 z
tance
86 HD785-7

2) Disconnect CUTF relay, connectors ABS1, ABS3, CVF and
CVSF.
3) Connect T-branch to ABS1 (female), ABS3 (female) and CUTF
Ground fault in wiring
5 harness (female), and carry out troubleshooting in this state.
(Contact with ground circuit) Between ABS1 (female) (23) – CVSF (1) Resis-
Max. 1 z
and ground tance
Possible causes
Between CVF (female) (1) – CUTF (3) and Resis-
and standard Max. 1 z
ground tance
value in normal
state Defective ABS cut-off valve
6 Replace ABS cut-off valve (F) to restore normal state.
(F)
2) Disconnect ABS1 and connect T-branch.
3) Connect T-branch to ABS1 (female).
7 Defective ABS controller 4) Start engine.
8 V/0 V
Between ABS1 (female) (23) – ground Voltage
change
HD785-7 87
Failure code [DWNEKZ] Trouble in ABS cut-off valve (Rear) system 1

Action code Failure code Trouble in ABS cut-off valve (Rear) system
Trouble
E03 DWNEKZ (ABS controller system)
• Large amount of current flows or the current does not flow when signal is output to the primary cir-
Contents of
cuit of ABS cut-off valve relay (Rear) (CUTR).
trouble
• The current flows when the ABS cut-off valve relay (Rear) (CUTR) is turned OFF.
Action of • Stop outputting to ABS cut-off valve relay (Rear) (CUTR)
controller (Interrupt ABS control)
Problem that
appears on
machine
• No signal is output to ABS cut-off valve relay (Rear) (CUTR) until starting switch is turned OFF.
Related
information • ABS controller is carrying out troubleshooting for the primary coil side of the ABS cut-off valve relay
(Rear) (CUTR).

2) Replace R11 (horn relay) and CUTR relay.
1 Defective relay (CUTR) 4) Sound the horn.
The horn sounds. Relay (CUTR) is normal.
Abnormal relay (CUTR)
(Replace).
2) Disconnect ABS3 and CUTR relay.
Disconnection in wiring 3) Connect T-branch to ABS3 (female) and CUTR (female) and
harness carry out troubleshooting in this state.
Resis-
Possible causes defective contact in connec- Between ABS3 (female) (18) – CUTR (1) Max. 1z
tor) tance
and standard
value in normal Resis-
Between ABS3 (female) (21) – CUTR (2) Max. 1z
state tance
2) Disconnect ABS3 and CUTR relay.
Ground fault in wiring 3) Connect T-branch to ABS3 (female) and CUTR (female) and
3 harness carry out troubleshooting in this state.
(Contact with ground circuit)
Min. 1 Mz
(female) (21) tance
2) Disconnect ABS3 and CUTR.
3) Connect T-branch to ABS3 (female) and CUTR (female).
4 Defective ABS controller 4) Turn the starting switch ON (without starting the engine).
5) Turn ABS switch ON-OFF.
Between ABS3 (female) (18) and ABS3 24 V/0 V
Voltage
(female) (21) change
88 HD785-7
HD785-7 89
Failure code [DWNEMA] Defective ABS cut-off valve (Rear) 1

Action code Failure code Defective ABS cut-off valve (Rear)
Trouble
E03 DWNEMA (ABS controller system)
Contents of • Command to ABS cut-off valve solenoid (Rear) does not match response from the ABS cut-off valve
trouble solenoid switch (Rear)
Action of • Stop outputting to ABS cut-off valve relay (Rear) (CUTR).
Problem that
appears on
machine
• ABS cut-off valve solenoid (Rear) is turned ON and OFF by turning the ABS cut-off valve relay
(Rear) (CUTR) ON and OFF.
Related
• No signal is output to ABS cut-off valve relay (Rear) (CUTR) until starting switch is turned OFF.
information
• ABS controller is carrying out troubleshooting for the primary coil side of the ABS cut-off valve relay
(Rear) (CUTR) with [DWNEKZ].

2) Replace R11 (horn relay) and CUTR relay.
1 Defective relay (CUTR) 4) Sound the horn.
The horn sounds. Relay (CUTR) is normal.
Abnormal relay (CUTR)
(Replace).
Defective solenoid of ABS 2) Disconnect connector CVR and carry out troubleshooting in
2 cut-off valve (Rear) this state.
(Internal disconnection) CVR (male) Resistance
Between (1) – (2) 10 – 30 z
2) Disconnect connector CVSR
3) Connect T-branch to connector CVSR and extend the wiring.
4) Start engine.
Possible causes Defective ABS cut-off sole- 5) Turn ABS switch ON and OFF.
3
and standard noid switch (Rear)
Resis-
value in normal OFF: between CVSR (1) – (2) Min. 1 Mz
tance
state
Resis-
ON: between CVSR (1) – (2) Max. 1 z
tance
2) Disconnect CUTR relay, connectors ABS1, ABS3, CVR and
CVSR.
3) Connect T-branch to ABS1 (female), ABS3 (female) and CUTR
(female) and CVSR (female), and carry out troubleshooting in
this state.
Disconnection in wiring Resis-
Between ABS3 (female) (2) – CUTR (5) Max. 1 z
harness tance
defective contact in connec- Between CVR (female) (1) – CUTR (3) Max. 1 z
tance
tor)
Resis-
Between CVR (female) (2) – chassis ground Max. 1 z
tance
Resis-
Between ABS1 (female) (17) – CVSR (1) Max. 1 z
tance
Resis-
Between ABS3 (female) (21) – CVSR (2) Max. 1 z
tance
90 HD785-7

2) Disconnect CUTR relay, connectors ABS1, ABS3, CVR and
CVSR.
3) Connect T-branch to ABS1 (female), ABS3 (female) and CUTR
Ground fault in wiring
5 harness (female), and carry out troubleshooting in this state.
(Contact with ground circuit) Between ABS1 (female) (17) – CVSR (1) Resis-
Max. 1 z
and ground tance
Possible causes
Between CVR (female) (1) – CUTR (3) and Resis-
and standard Max. 1 z
ground tance
value in normal
state Defective ABS cut-off valve
6 Replace ABS cut-off valve (R) to restore normal state.
(R)
2) Disconnect ABS1.
3) Connect T-branch to ABS1 (female).
7 Defective ABS controller 4) Start engine.
8 V/0 V
Between ABS1 (female) (17) – ground Voltage
change
HD785-7 91
HD785-7 Dump truck

© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (02)
92 HD785-7
SEN01946-02
HD785-7

HD785-7 7001 and up
Failure code [DX11K4] Rear brake proportional pressure reducing solenoid valve: Out of control ................ 4
Failure code [DX11KA] Rear brake proportional pressure reducing solenoid valve output circuit:
Disconnection .......................................................................................................................................... 6
Failure code [DX11KB] Rear brake proportional pressure reducing solenoid valve: Short circuit .................. 7
Failure code [DX11KY] Rear brake proportional pressure reducing solenoid valve:
Short circuit to power source line............................................................................................................. 8
Failure code [DX11MA] Rear brake proportional pressure reducing solenoid valve: Malfunction ................ 10
Failure code [DX12K4] Front brake proportional pressure reducing solenoid valve: Out of control ............. 12
Failure code [DX12KA] Front brake proportional pressure reducing solenoid valve output circuit:
Disconnection ........................................................................................................................................ 14
Failure code [DX12KB] Front brake proportional pressure reducing solenoid valve: Short circuit ............... 15
Failure code [DX12KY] Front brake proportional pressure reducing solenoid valve:
Short circuit to power source line........................................................................................................... 16
Failure code [DX12MA] Front brake proportional pressure reducing solenoid valve: Malfunction ............... 18
Failure code [DX13KA] Output circuit of hoist EPC valve: Disconnection .................................................... 20
Failure code [DX13KB] Output circuit of hoist EPC valve: Short circuit........................................................ 22
HD785-7 1
Failure code [DX13KY] Output circuit of hoist EPC valve: Short circuit with power source line ................... 24
Failure code [DX17K4] ASR proportional pressure reducing solenoid valve (right):
Trouble (Valve keeps operating) ............................................................................................................ 26
Failure code [DX17KA] ASR proportional pressure reducing solenoid valve (right) output circuit:
Disconnection ........................................................................................................................................ 28
Failure code [DX17KB] ASR proportional pressure reducing solenoid valve (right) output circuit:
Ground fault ........................................................................................................................................... 30
Failure code [DX17KY] ASR proportional pressure reducing solenoid valve (right) output circuit:
Short circuit ............................................................................................................................................ 32
Failure code [DX17MA] ASR proportional pressure reducing solenoid valve (right):
Trouble (Valve does not operate)........................................................................................................... 32
Failure code [DX18K4] ASR proportional pressure reducing solenoid valve (left):
Trouble (Valve keeps operating) ............................................................................................................ 34
Failure code [DX18KA] ASR proportional pressure reducing solenoid valve (left) output circuit:
Disconnection ........................................................................................................................................ 36
Failure code [DX18KB] ASR proportional pressure reducing solenoid valve (left) output circuit:
Ground fault ........................................................................................................................................... 38
Failure code [DX18KY] ASR proportional pressure reducing solenoid valve (left) output circuit:
Short circuit ............................................................................................................................................ 40
Failure code [DX18MA] ASR proportional pressure reducing solenoid valve (left):
Trouble (Valve does not operate)........................................................................................................... 40
Failure code [DX21KA] Disconnection in ABS control valve output circuit (Front right)................................ 41
Failure code [DX21KB] Ground fault in ABS control valve output circuit (Front right) .................................. 42
Failure code [DX21KY] Hot short in ABS control valve output circuit (Front right)........................................ 43
Failure code [DX21MA] Defective ABS control valve (Front right)................................................................ 44
Failure code [DX22KA] Disconnection in ABS control valve output circuit (Front left) .................................. 45
Failure code [DX22KB] Ground fault in ABS control valve output circuit (Front left)..................................... 46
Failure code [DX22KY] Hot short in ABS control valve output circuit (Front left) .......................................... 47
Failure code [DX22MA] Defective ABS control valve (Front left) .................................................................. 48
Failure code [DX23KA] Disconnection in ABS control valve output circuit (Rear right) ................................ 49
Failure code [DX23KB] Ground fault in ABS control valve output circuit (Rear right) ................................... 50
Failure code [DX23KY] Hot short in ABS control valve output circuit (Rear right) ........................................ 51
Failure code [DX23MA] Defective ABS control valve (Rear right) ................................................................ 52
Failure code [DX24KA] Disconnection in ABS control valve output circuit (Rear left) .................................. 53
Failure code [DX24KB] Ground fault in ABS control valve output circuit (Rear left) ..................................... 54
Failure code [DX24KY] Hot short in ABS control valve output circuit (Rear left) .......................................... 55
Failure code [DX24MA] Defective ABS control valve (Rear left)................................................................... 56
Failure code [DX25MA] Defective ABS front wheel system control valve..................................................... 57
Failure code [DX26MA] Defective ABS rear wheel system control valve ..................................................... 57
2 HD785-7
HD785-7 3
Failure code [DX11K4] Rear brake proportional pressure reducing

solenoid valve: Out of control 1
Action code Failure code Rear brake proportional pressure reducing solenoid valve: Out of
control
Trouble
E03 DX11K4 (Valve is stuck in operated condition)
(Retarder controller system)
• Rear brake proportional pressure reducing solenoid valve and solenoid keep operating and do not
Contents of
return or their condition cannot be judged normally because of defect in sensor switch after they
trouble
return.
Action of
• Continues control.
controller
Problem that • If solenoid is defective, rear brake drags.
appears on • If switch is defective or switch input circuit has ground fault, gear shift-up operation becomes difficult
machine and gear shift-down operation becomes easy.
Related • Retarder oil pressure switch state can be checked with monitoring function (Code: 40932)
information (bit [3], 0:OFF, 1:ON).

Defective rear brake • Check rear brake proportional pressure reducing solenoid valve.
1 proportional pressure If there is an abnormality (mechanical failure), repair or replace
reducing solenoid valve it.
2) Connect T-adapter to connector REVR (male).
Oil
Defective rear brake Resis-
pressure Max. 1 z
2 proportional pressure tance
is ON.
reducing solenoid Between REVR (male) (1) – (2)
Oil
Resis-
pressure Min. 1 Mz
tance
is OFF.
2) Connect T-adapter to connector RESWR.
3) Start engine.
Possible causes Defective retarder pressure
3 RESWR Retarder Voltage
and standard switch
value in normal When not operated 20 – 30 V
state Between (1) – (2)
When operated Max. 1 V
2) Disconnect connectors BRC1 and RESWR.
Defective harness grounding 3) Connect T-adapter to BRC1 (female).
4
(Contact with ground circuit) Between ground and wiring harness
Resis-
between BRC1 (female) (5) – RESWR Min. 1 Mz
tance
(female) (1)
2) Connect T-adapter to connector BRC3 (female).
Oil
pressure Voltage Max. 1 V
5 Defective retarder controller
is ON.
Between BRC3 (16) – (13)
Oil
pressure Voltage 10 – 30 V
is OFF.
4 HD785-7
HD785-7 5
Failure code [DX11KA] Rear brake proportional pressure reducing

solenoid valve output circuit: Disconnection 1
Action code Failure code Rear brake proportional pressure reducing solenoid valve output
Trouble circuit: Disconnection
E03 DX11KA (Retarder controller system)
Contents of • When output to rear brake proportional pressure reducing valve solenoid circuit is ON, current does
trouble not flow.
Action of
• Turn output to rear brake proportional pressure reducing valve solenoid OFF.
controller
Problem that
appears on • Retarder (rear brake) does not operate.
machine
Related
information

Defective rear brake
Resis-
1 proportional pressure Between REVR (male) (1) – (2) 10 – 30 z
tance
reducing solenoid valve
Resis-
Between REVR (female) (1), (2) – ground Min. 1 Mz
tance
Possible causes 1) Turn starting switch OFF.
and standard Disconnection in wiring 2) Connect T-adapter to connectors BRC3 (female) and REVR
value in normal harness (female).
state 2 (Disconnection in wiring or Wiring harness between BRC3 (female) Resis-
Max. 1 z
defective contact in connec- (16) – REVR (female) (1) tance
tor) Wiring harness between BRC3 (female) Resis-
Max. 1 z
(13) – REVR (female) (2) tance
Resis-
tance
6 HD785-7
Failure code [DX11KB] Rear brake proportional pressure reducing

solenoid valve: Short circuit 1
Action code Failure code Rear brake proportional pressure reducing solenoid valve: Short
Trouble circuit
E03 DX11KB (Retarder controller system)
Contents of • When output to solenoid circuit of rear brake proportional pressure reducing valve is turned ON,
trouble much current flows.
Action of
• Turns output to solenoid circuit of rear brake proportional pressure reducing valve OFF.
controller
Problem that
machine
Related
information

Resis-
tance
Resis-
tance
2) Disconnect connectors BRC3 and REVR.
Possible causes
and standard
value in normal Short circuit of harness Between ground and wiring harness
Resis-
state (Contact with ground between BRC3 (female) (16) – REVR Min. 1 Mz
2 tance
circuit or contact between (female) (1)
harnesses) Between wiring harness from BRC3
(female) (16) – REVR (female) (1) and wir- Resis-
Min. 1 Mz
ing harness from BRC3 (female) (13) – tance
REVR (female) (2)
Resis-
tance
HD785-7 7
Failure code [DX11KY] Rear brake proportional pressure reducing

solenoid valve: Short circuit to power source line 1
Action code Failure code Rear brake proportional pressure reducing solenoid valve: Short
Trouble circuit to power source line
E03 DX11KY (Retarder controller system)
Contents of • When output to rear brake proportional pressure reducing valve solenoid circuit is OFF, electric cur-
trouble rent flows.
Action of
• Turn output to rear brake proportional pressure reducing valve solenoid OFF.
controller
Problem that
machine
Related
information

Resis-
tance
Resis-
tance
and standard 2) Disconnect connectors BRC3 and REVR.
value in normal 3) Connect T-adapter to BRC3 (female).
state Hot short in wiring harness 4) Turn starting switch ON.
2
(a contact with 24 V circuit)
Between ground and wiring harness
between BRC3 (female) (16) – REVR Voltage Max. 1 V
(female) (1)
Resis-
tance
8 HD785-7
HD785-7 9
Failure code [DX11MA] Rear brake proportional pressure reducing

solenoid valve: Malfunction 1
Action code Failure code Rear brake proportional pressure reducing solenoid valve:
Trouble Malfunction
E03 DX11MA (Retarder controller system)
• Rear brake proportional pressure reducing solenoid valve and solenoid keep operating and do not
Contents of
trouble
return.
Action of
controller
Problem that
• If solenoid is defective, rear brake drags.
appears on
machine • If switch is defective or switch input circuit has disconnection, condition does not change.
Related • Condition of retarder oil pressure switch can be checked with monitoring function (Code: 40932)

Defective rear brake • Check rear brake proportional pressure reducing solenoid valve.
1 proportional pressure If there is an abnormality (mechanical failure), repair or replace
reducing solenoid valve it.
2) Connect T-adapter to connector REVR.
Resis-
tance
reducing solenoid
Resis-
Between REVR (female) (1), (2) and ground Min. 1 Mz
tance
2) Insert T-adapter in connector RESWR.
3) Start engine.
Defective retarder pressure
3 RESWR Retarder Voltage
switch
Possible causes
and standard When not operated 20 – 30 V
Between (1) – (2)
value in normal When operated Max. 1 V
state
2) Disconnect connectors BRC1 and RESWR.
Defective harness grounding 3) Connect T-adapter to BRC1.
4
Resis-
between BRC1 (female) (5) – RESWR Min. 1 Mz
tance
(female) (1)
2) Insert T-adapter in connector BRC3.
Oil
5 Defective retarder controller pressure Voltage Max. 1 V
is ON.
Oil
is OFF.
10 HD785-7
HD785-7 11
Failure code [DX12K4] Front brake proportional pressure reducing

solenoid valve: Out of control 1
Action code Failure code Front brake proportional pressure reducing solenoid valve: Out of
control
Trouble
E03 DX12K4 (Valve is stuck in operated condition)
(Retarder controller system)
• Front brake proportional pressure reducing solenoid valve and solenoid keep operating and do not
Contents of
trouble
return.
Action of
controller
Problem that • If solenoid is defective, front brake drags.
appears on • If switch is defective or switch input circuit has ground fault, gear shift-up operation becomes difficult
machine and gear shift-down operation becomes easy.
Related • Retarder oil pressure switch state can be checked with monitoring function (Code: 40932)

Defective front brake • Check front brake proportional pressure reducing solenoid
1 proportional pressure valve. If there is an abnormality (mechanical failure), repair or
reducing solenoid valve replace it.
2) Connect T-adapter to connector REVF (male).
Defective front brake
Resis-
2 proportional pressure Between REVF (male) (1) – (2) 10 – 30 z
tance
reducing solenoid
Resis-
Between REVF (female) (1), (2) and ground Min. 1 Mz
tance
2) Connect T-adapter to connector RESWF.
3) Start engine.
3 RESWF Retarder Voltage
Possible causes switch
value in normal Between (1) – (2)
state When operated Max. 1 V
2) Disconnect connectors BRC1 and RESWF.
Defective harness grounding 3) Connect T-adapter to BRC1 (female).
4
Resis-
between BRC1 (female) (11) – RESWF Min. 1 Mz
tance
(female) (1)
Oil
pressure Voltage Max. 1 V
is ON.
Oil
is OFF.
12 HD785-7
HD785-7 13
Failure code [DX12KA] Front brake proportional pressure reducing

solenoid valve output circuit: Disconnection 1
Action code Failure code Front brake proportional pressure reducing solenoid valve output
Contents of • When output to front brake proportional pressure reducing valve solenoid circuit is ON, current does
trouble not flow.
Action of
• Turn output to front brake proportional pressure reducing valve solenoid OFF.
controller
Problem that
appears on • Retarder (front brake) does not operate.
machine
Related
information

Resis-
tance
Resis-
Between REVF (female) (1), (2) – ground Min. 1 Mz
tance
and standard Disconnection in wiring 2) Connect T-adapter to connectors BRC3 (female) and REVF
value in normal harness (female).
state 2 (Disconnection in wiring or Wiring harness between BRC3 (female) (6) Resis-
Max. 1 z
defective contact in connec- – REVF (female) (1) tance
Max. 1 z
(13) – REVF (female) (2) tance
Resis-
tance
14 HD785-7
Failure code [DX12KB] Front brake proportional pressure reducing

solenoid valve: Short circuit 1
Action code Failure code Front brake proportional pressure reducing solenoid valve: Short
Trouble circuit
Contents of • When output to solenoid circuit of front brake proportional pressure reducing valve is turned ON,
trouble much current flows.
Action of
• Turns output to solenoid circuit of front brake proportional pressure reducing valve OFF.
controller
Problem that
machine
Related
information

Resis-
tance
Resis-
tance
2) Disconnect connectors BRC3 and REVF.
Possible causes
and standard
value in normal Short circuit of harness Between ground and wiring harness
Resis-
state (Contact with ground between BRC3 (female) (6) – REVF Min. 1 Mz
2 tance
circuit or contact between (female) (1)
harnesses) Between wiring harness from BRC3
(female) (6) – REVF (female) (1) and wiring Resis-
Min. 1 Mz
harness from BRC3 (female) (13) – REVF tance
(female) (2)
Resis-
tance
HD785-7 15
Failure code [DX12KY] Front brake proportional pressure reducing

solenoid valve: Short circuit to power source line 1
Action code Failure code Front brake proportional pressure reducing solenoid valve: Short
Trouble circuit to power source line
Contents of • When output to front brake proportional pressure reducing valve solenoid circuit is OFF, electric cur-
trouble rent flows.
Action of
• Turn output to front brake proportional pressure reducing valve solenoid OFF.
controller
Problem that
machine
Related
information

Resis-
tance
Resis-
tance
and standard 2) Disconnect connectors BRC3 and REVF.
value in normal 3) Connect T-adapter to BRC3 (female).
state Hot short in wiring harness 4) Turn starting switch ON.
2
(a contact with 24 V circuit)
between BRC3 (female) (6) – REVF Voltage Max. 1 V
(female) (1)
Resis-
tance
16 HD785-7
HD785-7 17
Failure code [DX12MA] Front brake proportional pressure reducing

solenoid valve: Malfunction 1
Action code Failure code Front brake proportional pressure reducing solenoid valve:
Trouble Malfunction
• Front brake proportional pressure reducing solenoid valve and solenoid keep operating and do not
Contents of
trouble
return.
Action of
controller
Problem that
• If solenoid is defective, front brake drags.
appears on
machine • If switch is defective or switch input circuit has disconnection, condition does not change.
Related • Condition of retarder oil pressure switch can be checked with monitoring function (Code: 40932)

Defective front brake • Check front brake proportional pressure reducing solenoid
1 proportional pressure valve. If there is an abnormality (mechanical failure), repair or
reducing solenoid valve replace it.
2) Connect T-adapter to connector REVF.
Resis-
tance
reducing solenoid
Resis-
Between REVF (female) (1), (2) and ground Min. 1 Mz
tance
2) Insert T-adapter in connector RESWF.
3) Start engine.
3 RESWF Retarder Voltage
switch
Possible causes
Between (1) – (2)
value in normal When operated Max. 1 V
state
2) Disconnect connectors BRC1 and RESWF.
Defective harness grounding 3) Connect T-adapter to BRC1.
4
Resis-
between BRC1 (female) (11) – RESWF Min. 1 Mz
tance
(female) (1)
2) Insert T-adapter in connector BRC3.
Oil
5 Defective retarder controller pressure Voltage Max. 1 V
is ON.
Oil
is OFF.
18 HD785-7
HD785-7 19
Failure code [DX13KA] Output circuit of hoist EPC valve:

Disconnection 1
Action code Failure code Output circuit of hoist EPC valve: Disconnection
Trouble
Contents of
• When the output to the hoist EPC solenoid circuit is ON, any current does not flow.
trouble
Action of • The controller turns the output to the hoist select valve solenoid OFF.
controller • The controller turns the output to the hoist EPC valve solenoid OFF.
Problem that
machine
Related
• This failure can be checked in the monitoring function (Code: 45600 (mA)).
information

2) Disconnect connector HEPC.
Defective hoist EPC valve
1 Resis-
solenoid Between HEPC (male) (1) – (2) 15 – 20 z
tance
Resis-
Between HEPC (female) (1), (2) – ground Min. 1 Mz
tance
and standard Disconnection in wiring 2) Disconnect connectors BRC3 and HEPC.
value in normal harness 3) Connect T-adapter.
state 2 (Disconnection in wiring or Wiring harness between BRC3 (female) (5) Resis-
Max. 1 z
defective contact in connec- – HEPC (female) (1) tance
Max. 1 z
(13) – HEPC (female) (2) tance
Resis-
tance
20 HD785-7
HD785-7 21
Failure code [DX13KB] Output circuit of hoist EPC valve: Short circuit 1
Action code Failure code Output circuit of hoist EPC valve: Short circuit
Trouble
Contents of
• When the output to the hoist EPC valve solenoid circuit is ON, a too large current flows.
trouble
Problem that
machine
Related
information

1 Resis-
tance
Resis-
tance
Possible causes 2) Disconnect connectors BRC3 and HEPC.
and standard 3) Connect T-adapter to BRC3 (female).
value in normal Grounding fault or short
state circuit in wiring harness Resis-
2 between BRC3 (female) (5) – HEPC Min. 1 Mz
(Contact with ground circuit tance
(female) (1)
or another wiring harness)
Resis-
– HEPC (female) (1) and between BRC3 Min. 1 Mz
tance
(female) (13) – HEPC (female) (2)
Resis-
tance
22 HD785-7
HD785-7 23
Failure code [DX13KY] Output circuit of hoist EPC valve: Short circuit
with power source line 1
Action code Failure code Output circuit of hoist EPC valve: Short circuit with power source
Trouble line
Contents of
• While the output to the hoist EPC valve solenoid circuit is OFF, some large current is flowing.
trouble
Problem that
machine
Related
information

1 Resis-
tance
Resis-
tance
2) Disconnect connectors BRC3 and HEPC.
Possible causes
and standard
4) Turn the starting switch ON.
value in normal Hot short in wiring harness
state Between ground and wiring harness
2 (Contact with power source
between BRC3 (female) (5) – HEPC Voltage Max. 1 V
wiring harness)
(female) (1)
between BRC3 (female) (13) – HEPC Voltage Max. 1 V
(female) (2)
Resis-
tance
24 HD785-7
HD785-7 25
Failure code [DX17K4] ASR proportional pressure reducing solenoid

valve (right): Trouble (Valve keeps operating) 1
Action code Failure code ASR proportional pressure reducing solenoid valve (right): Trouble
Trouble (Valve keeps operating)
E01 DX17K4 (Retarder controller system)
Contents of • ASR pressure sensor does not respond normally to ASR proportional pressure reducing solenoid
trouble valve (right) OFF command of retarder controller.
Action of
controller
Problem that
machine
Related MPa {3 kg/cm²} – 0.7 MPa {7 kg/cm²}, operation of sensor is unstable because of hysteresis.)
information • If ASR proportional pressure reducing solenoid valve (right) has electrical trouble, code [DX17KA],
[DX17KB] or [DX17KY] is output.

a ASR proportional pressure reducing solenoid valve (right) may
Defective ASR proportional have mechanical trouble. Check it directly.
1 pressure reducing solenoid
valve (right) If the failure is repaired by replacing the ASR valve (right), the ASR
valve (right) is defective.
2) Disconnect ASR6 and insert jig in ASR6 (male) (Keep ASR6
Defective ASR pressure (female) disconnected).
2 3) Turn starting switch OFF and ON (Keep ASR switch OFF).
sensor
Between ASR6 (male) (1) – ASR6 (male) Resis-
Min. 1 Mz
Possible causes (2) tance
and standard a Turn starting switch OFF and disconnect ASR6 and BRC3, then
value in normal Disconnection in wiring carry out troubleshooting without turning starting switch ON.
state harness
(female) (10) tance
connector) Between ASR6 (female) (2) – BRC3 Resis-
Max. 1 z
(female) (21) tance
4 harness
Min. 1 Mz
tance
out.)
26 HD785-7
HD785-7 27
Failure code [DX17KA] ASR proportional pressure reducing solenoid

valve (right) output circuit: Disconnection 1
Action code Failure code ASR proportional pressure reducing solenoid valve (right) output
Contents of • When signal is output to ASR proportional pressure reducing solenoid valve (right) solenoid circuit,
trouble no current flows.
Action of
controller
Problem that
machine
Related • Signal is not output to ASR proportional pressure reducing solenoid valve (right) solenoid circuit
information until starting switch is turned OFF once.
Defective ASR proportional a Turn starting switch OFF and disconnect ASR4, then carry out
pressure reducing solenoid troubleshooting without turning starting switch ON.
1
valve (right) solenoid (Inter- ASR4 (male) Resistance
nal disconnection) Between (1) – (2) 20 z
Between J04 (male) (36) – (37) 20 z
connector) Resis-
Between BRC3 (female) (26) – (23) 20 z
tance
carried out.)
28 HD785-7
HD785-7 29
Failure code [DX17KB] ASR proportional pressure reducing solenoid

valve (right) output circuit: Ground fault 1
Trouble circuit: Ground fault
trouble abnormal current flows.
Action of
controller
Problem that
machine
1
valve (right) solenoid (Inter- ASR4 (male) Resistance
nal short circuit) Between (1) – (2) 20 z
2 harness
tance
and standard
state
3 harness
Min. 1 Mz
4
out.)
30 HD785-7
HD785-7 31
Failure code [DX17KY] ASR proportional pressure reducing solenoid

valve (right) output circuit: Short circuit 1
Trouble circuit: Short circuit
Action of
controller
Problem that
machine

and standard
value in normal Carry out troubleshooting for failure code [DX17KB].
state
Failure code [DX17MA] ASR proportional pressure reducing solenoid

valve (right): Trouble (Valve does not operate) 1
Action code Failure code ASR proportional pressure reducing solenoid valve (right): Trouble
Trouble (Valve does not operate)
Contents of • ASR pressure sensor does not respond to ASR proportional pressure reducing solenoid valve
trouble (right) ON command of retarder controller.
Action of
controller
Problem that
machine
information • If ASR proportional pressure reducing solenoid valve (right) has electrical trouble, code [DX17KA],

and standard
value in normal Carry out troubleshooting for failure code [DX17K4].
state
32 HD785-7
HD785-7 33
Failure code [DX18K4] ASR proportional pressure reducing solenoid

valve (left): Trouble (Valve keeps operating) 1
Action code Failure code ASR proportional pressure reducing solenoid valve (left): Trouble
Trouble (Valve keeps operating)
Contents of • ASR pressure sensor does not respond normally to ASR proportional pressure reducing solenoid
trouble valve (left) OFF command of retarder controller.
Action of
controller
Problem that
machine
information • If ASR proportional pressure reducing solenoid valve (left) has electrical trouble, code [DX18KA],

a ASR proportional pressure reducing solenoid valve (left) may
Defective ASR proportional have mechanical trouble. Check it directly.
1 pressure reducing solenoid
valve (left) If the failure is repaired by replacing the ASR valve (left), the ASR
valve (left) is defective.
2) Disconnect ASR5 and insert jig in ASR5 (male) (Keep ASR5
Defective ASR pressure (female) disconnected).
2 3) Turn starting switch OFF and ON (Keep ASR switch OFF).
sensor
Between ASR5 (male) (1) – ASR5 (male) Resis-
Min. 1 Mz
Possible causes (2) tance
and standard a Turn starting switch OFF and disconnect ASR5 and BRC3, then
value in normal Disconnection in wiring carry out troubleshooting without turning starting switch ON.
state harness
(female) (20) tance
connector) Between ASR5 (female) (2) – BRC3 Resis-
Max. 1 z
(female) (21) tance
4 harness
Min. 1 Mz
tance
out.)
34 HD785-7
HD785-7 35
Failure code [DX18KA] ASR proportional pressure reducing solenoid

valve (left) output circuit: Disconnection 1
Action code Failure code ASR proportional pressure reducing solenoid valve (left) output
Contents of • When signal is output to ASR proportional pressure reducing solenoid valve (left) solenoid circuit,
trouble no current flows.
Action of
controller
Problem that
machine
Related • Signal is not output to ASR proportional pressure reducing solenoid valve (left) solenoid circuit until
information starting switch is turned OFF once.
1
valve (left) solenoid (Internal ASR3 (male) Resistance
disconnection) Between (1) – (2) 20 z
Between J04 (male) (38) – (39) 20 z
connector) Resis-
Between BRC3 (female) (36) – (23) 20 z
tance
carried out.)
36 HD785-7
HD785-7 37
Failure code [DX18KB] ASR proportional pressure reducing solenoid

valve (left) output circuit: Ground fault 1
Trouble circuit: Ground fault
Action of
controller
Problem that
machine
1
valve (left) solenoid (Internal ASR3 (male) Resistance
short circuit) Between (1) – (2) 20 z
2 harness
tance
and standard
state
3 harness
Min. 1 Mz
4
out.)
38 HD785-7
HD785-7 39
Failure code [DX18KY] ASR proportional pressure reducing solenoid

valve (left) output circuit: Short circuit 1
Trouble circuit: Short circuit
Action of
controller
Problem that
machine

and standard
value in normal Carry out troubleshooting for failure code [DX18KB].
state
Failure code [DX18MA] ASR proportional pressure reducing solenoid

valve (left): Trouble (Valve does not operate) 1
Action code Failure code ASR proportional pressure reducing solenoid valve (left): Trouble
Trouble (Valve does not operate)
Contents of • ASR pressure sensor does not respond to ASR proportional pressure reducing solenoid valve (left)
trouble ON command of retarder controller.
Action of
controller
Problem that
machine
information • If ASR proportional pressure reducing solenoid valve (left) has electrical trouble, code [DX18KA],

and standard
value in normal Carry out troubleshooting for failure code [DX18K4].
state
40 HD785-7
Failure code [DX21KA] Disconnection in ABS control valve output

circuit (Front right) 1
Action code Failure code Disconnection in ABS control valve output circuit (Front right)
Trouble
E03 DX21KA (ABS controller system)
Contents of
• No current flows when the signal is output to the ABS control valve (Front right) solenoid circuit.
trouble
Action of • Stop outputting to ABS control valve (Front right) solenoid circuit.
Problem that
appears on
• Output to ABS control valve (front right-hand) solenoid can be checked with the monitoring function.
Related
(Code: 43309, output current (0 – 1000 (mA))
information
• No signal is output to ABS control valve solenoid until starting switch is turned OFF.

2) Disconnect connector ABSFR.
Defective solenoid (internal 3) Connect the T-branch to connector ABSFR and carry out trou-
1 disconnection) in ABS con- bleshooting in this state.
trol valve
ABSFR (male) Resistance
Between (1) – (2) 10 – 30 z
Possible causes 2) Disconnect connectors ABSFR and ABS3.
and standard Disconnection in wiring 3) Connect the T-branch to connectors ABSFR and ABS3 and
value in normal harness carry out troubleshooting in this state.
state 2 (Disconnection in wiring or
Resis-
defective contact in connec- Between ABS3 (female) (3) and ABSFR (2) Max. 1 z
tance
tor)
Resis-
Between ABS3 (female) (6) and ABSFR (1) Max. 1 z
tance
2) Disconnect connector ABS3.
3 Defective ABS controller 3) Connect T-branch.
10 – 30 z
(female) (3) terminals tance
HD785-7 41
Failure code [DX21KB] Ground fault in ABS control valve output circuit
(Front right) 1
Action code Failure code Ground fault in ABS control valve output circuit (Front right)
Trouble
E03 DX21KB (ABS controller system)
Contents of
• Abnormal current flows when signal is output to ABS control valve (Front right) solenoid circuit.
trouble
Problem that
appears on
• Output to ABS control valve (front right-hand) solenoid can be checked with the monitoring function.
Related
information

Defective solenoid (internal 3) Connect the T-branch to connector ABSFR and carry out trou-
1 disconnection) in ABS con- bleshooting in this state.
trol valve
ABSFR (male) Resistance
Between (1) – (2) 10 – 30 z

and standard 2) Disconnect connectors ABSFR and ABS3.
value in normal Ground fault in wiring 3) Connect the T-branch to connector ABS3 and carry out trouble-
state 2 harness shooting in this state.
(Contact with ground circuit) (With connectors ABSFR and ABS3 being disconnected).
Resis-
Between ABS3 (female) (6) and ground Max. 1 Mz
tance
10 – 30 z
42 HD785-7
Failure code [DX21KY] Hot short in ABS control valve output circuit
(Front right) 1
Action code Failure code Hot short in ABS control valve output circuit (Front right)
Trouble
E03 DX21KY (Transmission controller system)
Contents of
• Abnormal current flows when no signal is output to ABS control valve solenoid circuit.
trouble
Problem that
appears on
• Output to ABS control valve (Front right) solenoid can be checked with the monitoring function.
Related
information

3) Connect the T-branch to connector ABSFR and carry out trou-
Defective solenoid (internal
bleshooting in this state.
1 hot short) in ABS control
valve ABSFR (male) Resistance
Between (1) – (2) 10 – 30 z
Between (1), (2) – ground Min. 1 Mz
Possible causes
value in normal 2) Disconnect connectors ABS3 and ABSFR.
Hot short circuit in wiring 3) Connect the T-branch to ABS3.
state
2 harness (With connector ABSFR being disconnected).
(Contact with 24-V circuit) 4) Carry out troubleshooting with the starting switch ON.
Between ABS3 (female) (6) and ground Voltage Max. 1 V
10 – 30 z
HD785-7 43
Failure code [DX21MA] Defective ABS control valve (Front right) 1

Action code Failure code Defective ABS control valve (Front right)
Trouble
E03 DX21MA (ABS controller system)
Contents of • Command to ABS control valve (Front right) does not match response from ABS control valve pres-
trouble sure sensor.
Problem that
appears on
• Troubleshooting for ABS control valve (Front right) solenoid circuit is carried out with [DX21KA],
[DX21KB] and [DX21KY].
Related • Troubleshooting for ABS control valve (Front right) pressure sensor is carried out with [DHU6KX].
information • Output to ABS control valve (Front right) solenoid can be checked with the monitoring function.

If failure codes [DX21KA], [DX21KB], [DX21KY] and [DHU6KX] are displayed, carry out trouble-
1
Possible causes shooting for them.
and standard Defective ABS control valve Main pressure variable valve may be damaged mechanically.
2
value in normal (Front right) Check it directly.
state 3 Defective hydraulic piping Hydraulic piping may be damaged. Check it directly.
If causes 1 – 3 are not detected, ABS controller may be defective.
4 Defective ABS controller
(Since trouble is in system, troubleshooting cannot be carried out.)
44 HD785-7

circuit (Front left) 1
Action code Failure code Disconnection in ABS control valve output circuit (Front left)
Trouble
Contents of
• No current flows when the signal is output to the ABS control valve (Front left) solenoid circuit.
trouble
Action of • Stop outputting to ABS control valve (Front left) solenoid circuit.
Problem that
appears on
• Output to ABS control valve (Front left) solenoid can be checked with the monitoring function.
Related
information

2) Disconnect connector ABSFL.
Defective ABS control valve 3) Connect the T-branch to connector ABSFL and carry out trou-
1 solenoid bleshooting with the starting switch OFF.
ABSFL (male) Resistance
Between (1) – (2) 10 – 30 z
Possible causes 2) Disconnect connector ABSFL and ABS3.
and standard Disconnection in wiring 3) Connect the T-branch to connectors ABSFL and ABS3, and
value in normal harness carry out troubleshooting with the starting switch OFF.
Wiring harness between ABS3 (female) (3) Resis-
– ABSFL (2) tance
tor)
Max. 1 z
– ABSFL (1) tance
10 – 30 z
– ABS3 (female) (3) tance
HD785-7 45
(Front left) 1
Action code Failure code Ground fault in ABS control valve output circuit (Front left)
Trouble
Contents of
• Abnormal current flows when signal is output to ABS control valve (Front left) solenoid circuit.
trouble
Problem that
appears on
Related
information

Defective ABS control valve 3) Connect the T-branch to connector ABSFL and carry out trou-
ABSFL (male) Resistance
Between (1) – (2) 10 – 30 z

and standard 2) Disconnect connector ABSFL and ABS3.
state 2 harness shooting with the starting switch OFF.
(Contact with ground circuit) (With connectors ABSFL and ABS3 disconnected)
Resis-
tance
10 – 30 z
– ABS3 (female) (3) terminal tance
46 HD785-7
(Front left) 1
Action code Failure code Hot short in ABS control valve output circuit (Front left)
Trouble
Contents of
trouble
Problem that
appears on
Related
information

3) Connect the T-branch to connector ABSFL and carry out trou-
Defective ABS control valve
bleshooting with the starting switch OFF.
1 solenoid
(Internal hot short) ABSFL (male) Resistance
Between (1) – (2) 10 – 30 z
Possible causes
value in normal 2) Disconnect connectors ABS3 and ABSFL.
Hot short circuit in wiring 3) Connect T-branch to connector ABS3.
state
2 harness (With connector ABSFL being disconnected)
(Contact with 24V circuit) 4) Turn starting switch ON and carry out troubleshooting.
10 – 30 z
HD785-7 47
Failure code [DX22MA] Defective ABS control valve (Front left) 1

Action code Failure code Defective ABS control valve (Front left)
Trouble
Contents of • Command to ABS control valve (Front left) does not match response from ABS control valve pres-
Problem that
appears on
• Troubleshooting for ABS control valve (Front left) solenoid circuit is carried out with [DX22KA],
Related • Troubleshooting for ABS control valve (Front left) pressure sensor is carried out with [DHU7KX].
information • Output to ABS control valve (Front left) solenoid can be checked with the monitoring function.

1
2
value in normal (Front left) Check it directly.
state 3 Defective hydraulic piping Hydraulic piping may be defective. Check it directly.
(Since trouble is in system, troubleshooting is disabled.)
48 HD785-7

circuit (Rear right) 1
Action code Failure code Disconnection in ABS control valve output circuit (Rear right)
Trouble
Contents of
• No current flows when the signal is output to the ABS control valve (Rear right) solenoid circuit.
trouble
Action of • Stop outputting to ABS control valve (Rear right) solenoid circuit.
Problem that
appears on
• Output to ABS control valve (Rear right) solenoid can be checked with the monitoring function.
Related
information

2) Disconnect connector ABSRR.
Defective ABS control valve 3) Connect the T-branch to connector ABSRR and carry out trou-
1 solenoid bleshooting in this state.
ABSRR (male) Resistance
Between (1) – (2) 10 – 30 z
Possible causes 2) Disconnect connectors ABSRR and ABS3.
and standard Disconnection in wiring 3) Connect the T-branch to connectors ABSRR and ABS3, and
– ABSRR (2) tance
tor)
Max. 1 z
– ABSRR (1) tance
10 – 30 z
HD785-7 49
(Rear right) 1
Action code Failure code Ground fault in ABS control valve output circuit (Rear right)
Trouble
Contents of
• Abnormal current flows when signal is output to ABS control valve (Rear right) solenoid circuit.
trouble
Problem that
appears on
Related
information

Defective ABS control valve 3) Connect the T-branch to connector ABSRR and carry out trou-
1 solenoid bleshooting in this state.
ABSRR (male) Resistance
Between (1) – (2) 10 – 30 z

and standard 2) Disconnect connectors ABSRR and ABS3.
state 2 harness shooting in this state.
(Contact with ground circuit) (With connectors ABSRR and ABS3 being disconnected)
Resis-
tance
10 – 30 z
50 HD785-7
(Rear right) 1
Action code Failure code Hot short in ABS control valve output circuit (Rear right)
Trouble
Contents of
trouble
Problem that
appears on
Related
information

3) Connect the T-branch to connector ABSRR and carry out trou-
bleshooting in this state.
1 solenoid
(Internal hot short) ABSRR (male) Resistance
Between (1) – (2) 10 – 30 z
Possible causes
value in normal 2) Disconnect connectors ABS3 and ABSRR.
Hot short circuit in wiring 3) Connect T-branch to connector ABS3.
state
2 harness (With connector ABSRR being disconnected)
(Contact with 24-V circuit) 4) Carry out troubleshooting with the starting switch turned ON.
10 – 30 z
HD785-7 51
Failure code [DX23MA] Defective ABS control valve (Rear right) 1

Action code Failure code Defective ABS control valve (Rear right)
Trouble
Contents of • Command to ABS control valve (Rear right) does not match response from ABS control valve pres-
Problem that
appears on
• Troubleshooting for ABS control valve (Rear right) solenoid circuit is carried out with [DX23KA],
Related • Troubleshooting for ABS control valve (Rear right) pressure sensor is carried out with [DHU8KX].
information • Output to ABS control valve (Rear right) solenoid can be checked with the monitoring function.

1
2
value in normal (Rear right) Check it directly.
52 HD785-7

circuit (Rear left) 1
Action code Failure code Disconnection in ABS control valve output circuit (Rear left)
Trouble
Contents of
• No current flows when the signal is output to the ABS control valve (Rea left) solenoid circuit.
trouble
Action of • Stop outputting to ABS control valve (Rear left) solenoid circuit.
Problem that
appears on
• Output to ABS control valve (Rear left) solenoid can be checked with the monitoring function.
Related
information

2) Disconnect connector ABSRL.
Defective ABS control valve 3) Connect the T-branch to connector ABSRL and carry out trou-
ABSRL (male) Resistance
Between (1) – (2) 10 – 30 z
Possible causes 2) Disconnect connector ABSRL and ABS3.
and standard Disconnection in wiring 3) Connect the T-branch to connectors ABSRL and ABS3, and
– ABSRL (2) tance
tor)
Max. 1 z
– ABSRL (1) tance
10 – 30 z
HD785-7 53
(Rear left) 1
Action code Failure code Ground fault in ABS control valve output circuit (Rear left)
Trouble
Contents of
• Abnormal current flows when signal is output to ABS control valve (Rear left) solenoid circuit.
trouble
Problem that
appears on
Related
information

Defective ABS control valve 3) Connect the T-branch to connector ABSRL and carry out trou-
ABSRL (male) Resistance
Between (1) – (2) 10 – 30 z

and standard 2) Disconnect connector ABSRL and ABS3.
state 2 harness shooting with the starting switch OFF.
(Contact with ground circuit) (With connectors ABSRL and ABS3 being disconnected)
Resis-
tance
10 – 30 z
54 HD785-7
(Rear left) 1
Action code Failure code Hot short in ABS control valve output circuit (Rear left)
Trouble
Contents of
trouble
Problem that
appears on
Related
information

3) Connect the T-branch to connector ABSRL and carry out trou-
bleshooting with the starting switch OFF.
1 solenoid
(Internal hot short) ABSRL (male) Resistance
Between (1) – (2) 10 – 30 z
and standard 2) Disconnect connectors ABS3 and ABSRL.
value in normal 3) Connect T-branch to connector ABS3.
Hot short circuit in wiring
state (With connector ABSRL being disconnected)
2 harness
(Contact with 24-V circuit) 4) Turn starting switch ON and carry out troubleshooting.
Between ABS3 (female) (36) and chassis
Voltage Max. 1 V
ground
10 – 30 z
HD785-7 55
Failure code [DX24MA] Defective ABS control valve (Rear left) 1

Action code Failure code Defective ABS control valve (Rear left)
Trouble
Contents of • Command to ABS control valve (Rear left) does not match response from ABS control valve pres-
Problem that
appears on
• Troubleshooting for ABS control valve (Rear left) solenoid circuit is carried out with [DX24KA],
Related • Troubleshooting for ABS control valve (Rear left) solenoid circuit is carried out with [DHU9KX].
information • Output to ABS control valve (Rear left) solenoid can be checked with the monitoring function.

1
2
value in normal (Rear left) Check it directly.
56 HD785-7
Failure code [DX25MA] Defective ABS front wheel system control valve 1
Action code Failure code Defective ABS front wheel system control valve
Trouble
• Command to ABS control valve (Front) does not match response from ABS control valve pressure
Contents of
sensor switch.
trouble
(Front right or front left)
Action of • Stop outputting to ABS control valve (Front) solenoid circuit.
Problem that
appears on
• Check for front right or front left according to failure codes [DX21MA] (front right) and [DX22MA]
Related
(front left) output elsewhere.
information

and standard
value in normal 1 Carry out troubleshooting for [DX21MA] or [DX22MA].
state
Failure code [DX26MA] Defective ABS rear wheel system control valve 1
Action code Failure code Defective ABS rear wheel system control valve
Trouble
• Command to ABS control valve (Rear) does not match response from ABS control valve pressure
Contents of
sensor switch.
trouble
(Rear right or rear left)
Action of • Stop outputting to ABS control valve (Rear) solenoid circuit.
Problem that
appears on
• Check for rear right or rear left according to failure codes [DX23MA] (rear right) and [DX24MA] (rear
Related
left) output elsewhere.
information

and standard
value in normal 1 Carry out troubleshooting for [DX23MA] or [DX24MA].
state
HD785-7 57
HD785-7 Dump truck

© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (02)
58 HD785-7
SEN01947-02
HD785-7

HD785-7 7001 and up
Failure code [DXH1KA] Lockup clutch solenoid output circuit: Disconnection ............................................... 4
Failure code [DXH1KB] Lockup clutch solenoid output circuit: Short circuit ................................................... 6
Failure code [DXH1KY] Lockup clutch solenoid output circuit: Short circuit to power supply line .................. 8
Failure code [DXH2KA] Hi clutch solenoid output circuit: Disconnection...................................................... 10
Failure code [DXH2KB] Hi clutch solenoid output circuit: Short circuit ......................................................... 12
Failure code [DXH2KY] Hi clutch solenoid output circuit: Short circuit to power supply line ........................ 14
Failure code [DXH3KA] Lo clutch solenoid output circuit: Disconnection ..................................................... 18
Failure code [DXH3KB] Lo clutch solenoid output circuit: Short circuit......................................................... 20
Failure code [DXH3KY] Lo clutch solenoid output circuit: Short circuit in power supply line ........................ 22
Failure code [DXH4KA] 1st clutch solenoid output circuit: Disconnection .................................................... 26
Failure code [DXH4KB] 1st clutch solenoid output circuit: Short circuit........................................................ 28
Failure code [DXH4KY] 1st clutch solenoid output circuit: Short circuit to power supply line ....................... 30
Failure code [DXH5KA] 2nd clutch solenoid output circuit: Disconnection ................................................... 34
Failure code [DXH5KB] 2nd clutch solenoid output circuit: Short circuit....................................................... 36
Failure code [DXH5KY] 2nd clutch solenoid output circuit: Short circuit in power supply line ...................... 38
Failure code [DXH6KA] 3rd clutch solenoid output circuit: Disconnection.................................................... 42
HD785-7 1
Failure code [DXH6KB] 3rd clutch solenoid output circuit: Short circuit........................................................ 44
Failure code [DXH6KY] 3rd clutch solenoid output circuit: Short circuit to power supply line....................... 46
Failure code [DXH7KA] R clutch solenoid output circuit: Disconnection....................................................... 50
Failure code [DXH7KB] R clutch solenoid output circuit: Short circuit .......................................................... 52
Failure code [DXH7KY] R clutch solenoid output circuit: Short circuit to power supply line ......................... 54
Failure code [DXHHKA] 4th clutch solenoid output circuit: Disconnection.................................................... 56
Failure code [DXHHKB] 4th clutch solenoid output circuit: Short circuit ....................................................... 58
Failure code [DXHHKY] 4th clutch solenoid output circuit: Short circuit to power supply line ...................... 60
Failure code [F@BBZL] or VHMS_LED display: "n3"o"38" Blow-by pressure: High error........................... 63
Failure code [F@BYNS] (or VHMS_LED display "n3" o "61") Left front exhaust temperature sensor (1):
Exhaust temperature abnormal rise....................................................................................................... 64
Failure code [f@BYNS] (or VHMS_LED display "n3" o "71") Left rear exhaust temperature sensor (1):
Failure code [F@BZNS] (or VHMS_LED display "n3" o "81") Right front exhaust temperature sensor (1):
Failure code [f@BZNS] (or VHMS_LED display "n3" o "91") Right rear exhaust temperature sensor (1):
Failure code [F@BYNR] (or VHMS_LED display "n3" o "62") Left front exhaust temperature sensor (2):
Failure code [f@BYNR] (or VHMS_LED display "n3" o "72") Left rear exhaust temperature sensor (2):
Failure code [F@BZNR] (or VHMS_LED display "n3" o "82") Right front exhaust temperature sensor (2):
Failure code [f@BZNR] (or VHMS_LED display "n3" o "92") Right rear exhaust temperature sensor (2):
2 HD785-7
HD785-7 3
Failure code [DXH1KA] Lockup clutch solenoid output circuit:

Disconnection 1
Action code Failure code Lockup clutch solenoid output circuit: Disconnection
Trouble
E03 DXH1KA (Transmission controller system)
Contents of
trouble • When signal is output to lockup clutch solenoid, no current flows.
• Keeps gear speed used for travel.

Action of
controller • Turns lockup operation OFF.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that • Lockup system does not operate.
appears on
machine • If gearshift lever is set in N, machine cannot restart until it stops.
• As controller detects disconnection of solenoid while output is ON, be sure to turn output ON to
check operation after repair.
• Output current to lockup solenoid can be checked with monitoring function (Code: 31609 (mA)).
Related infor- • Since output is turned ON and self-check is performed for 5 seconds after starting switch is turned
mation ON, wait for 5 seconds without starting the engine.
• If trouble has not been repaired, error is detected again.
k Raise the body at the highest position, and set damp lever to "Hold", and install body lock
pin to right and left.

2) Disconnect connector L/U.PS (CN16).
3) Connect T-adapter to connector L/U.PS (CN16) (male).
Defective lockup clutch
1 Resis-
solenoid Between L/U.PS (CN16) (male) (1) and (2) 5 – 15 z
tance
Between L/U.PS (CN16) (male) (1) or (2) Resis-
Min. 1 Mz
and ground tance
Disconnection or short circuit 3) Connect T-adapter to connector ATC3 (female).
2
in wiring harness
and standard Between ATC3 (female) (35) and (23) 5 – 15 z
tance
value in normal
a If no abnormality is found in check on cause 2, this check is
state
not required.
Disconnection in wiring 2) Disconnect connectors ATC3 and L/U.PS (CN16).
harness 3) Connect T-adapters to connectors ATC3 (female) and L/U.PS
3 (CN16) (female).
(Disconnection or improper
contact) Between ATC3 (female) (35) and L/U.PS Resis-
Max. 1 z
(CN16) (female) (1) tance
Between ATC3 (female) (23) and L/U.PS Resis-
Max. 1 z
If causes are not found by above checks, transmission controller is
Defective transmission con-
4 defective. (Since this is an internal failure, troubleshooting can not
troller
be performed.)
4 HD785-7
HD785-7 5
Failure code [DXH1KB] Lockup clutch solenoid output circuit: Short cir-
cuit 1
Action code Failure code Lockup clutch solenoid output circuit: Short circuit
Trouble
E03 DXH1KB (Transmission controller system)
Contents of • When signal is output to lockup clutch solenoid, much current flows, or while signal is OFF, some
trouble current flows.
Action of • Keeps gear speed used for travel and turns lockup operation OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that • Lockup system is kept OFF.
appears on
machine • If gearshift lever is set in N, machine cannot restart until it stops.
• Output current to lockup solenoid can be checked with monitoring function (Code: 31609 (mA)).
Related infor-
mation

2) Disconnect connector L/U.PS (CN16)
1 Resis-
tance
Min. 1 Mz
and ground tance
2
in wiring harness
Resis-
Between ATC3 (female) (35) and (23) 5 – 15 z
tance
Possible causes
and standard 1) Turn starting switch OFF.
value in normal 2) Disconnect connectors ATC3 and L/U.PS (CN16).
state Ground fault in wiring har- 3) Connect T-adapter to ATC3 or L/U.PS (CN16) (female).
3
ness Between ground and ATC3 (female) (35)
Resis-
and (23) or between L/U.PS (CN16) (female) Min. 1 Mz
tance
(1) and (2)
not required.
Short circuit in wiring har- 2) Disconnect connectors ATC3 and L/U.PS (CN16).
4
ness 3) Connect T-adapter to ATC3 or L/U.PS (CN16) (female).
Between ATC3 (female) (35) and (23) or Resis-
Min. 1 Mz
between L/U.PS (CN16) (female) (1) and (2) tance
troller
be performed.)
6 HD785-7
HD785-7 7
Failure code [DXH1KY] Lockup clutch solenoid output circuit: Short cir-
cuit to power supply line 1
Action code Failure code Lockup clutch solenoid output circuit: Short circuit to power supply
Trouble line
E03 DXH1KY (Transmission controller system)
Contents of
trouble • While output to lock-up clutch solenoid is OFF, electric current flows.
Action of • Keeps gear speed used for travel and turns lockup operation OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that • Cannot change gear speed.
appears on • Keeps lockup OFF
machine • When gear shift lever is operated to N, machine cannot move off.
• Output current to lockup solenoid can be checked with monitoring function (Code: 31609 (mA))
Related infor-
mation

1 Resis-
tance
Min. 1 Mz
and ground tance
3) Connect T-adapter to connector L/U.PS (CN16) (female) or
insert T-adapter into connector ATC3.
Hot short in wiring harness 4) Turn starting switch ON.
2
(Contact with 24 V circuit) a If failure code [DXH1KA] for disconnection appears, hot short
circuit is not present. (Lockup clutch solenoid is defective.)
Between ground and ATC3 (35) or L/U.PS
Voltage Max. 1 V
(CN16) (female) (1)
Possible causes 1) Turn the starting switch to OFF position.
and standard 2) Disconnect connectors ATC3 and L/U.PS (CN16).
value in normal 3) Connect the T-adapter to connector ATC3 (female).
state a Use the continuity range of the multimeter for the measure-
ment.
Between ATC3 (female) (35) and each pin No continuity
other than pin (35). (No sound is heard)
1) Turn the starting switch to OFF position.
2) Disconnect connectors ATC3, J05, TM3, and L/U.PS (CN16).
3) Connect the T-adapter to either male or female side of connec-
Short circuit in wiring har- tors J05 or TM3.
3
ness a Use the continuity range of the multimeter for the measure-
ment.
Between TM3 (female) (12) and each pin No continuity
other than (12) (No sound is heard)
Between TM3 (male) (12) and each pin No continuity
Between J05 (female) (26) and each pin No continuity
Between J05 (male) (26) and each pin other No continuity
than (26) (No sound is heard)
8 HD785-7

and standard If no abnormality was found in the above troubleshooting, the
value in normal Defective transmission con-
4 transmission controller is defective. (Since this is an internal
state troller
defect, troubleshooting cannot be performed.)
HD785-7 9
Failure code [DXH2KA] Hi clutch solenoid output circuit: Disconnection1

Action code Failure code Hi clutch solenoid output circuit: Disconnection
Trouble
Contents of
trouble • No electric current flows when the output to Hi clutch ECMV solenoid is ON.
• Shifts up and holds the gear speed as shown in Table 1 depending on the gear speed before fail-
Action of
ure.
controller
• Turns lock up to OFF.
Problem that
appears on • Once the gear shift lever is set to neutral, the machine can not move off in any gear speeds.
machine
• Electric current of output to ECMV can be checked with monitoring function (code: 31600 (mA)).
Related infor- • Since output is turned ON and self-check is performed for 5 seconds after starting switch is turned
mation ON, wait for 5 seconds without starting the engine.

2) Disconnect connector H.PS (CN19).
3) Connect T-adapter to connector H.PS (CN19) (male).
Defective Hi clutch ECMV
1 Resis-
solenoid Between H.PS (CN19) (male) (1) and (2) 5 – 15 z
tance
Between H.PS (CN19) (male) (1) or (2) and Resis-
Min. 1 Mz
ground tance
2
in wiring harness
tance
value in normal
state
not required.
Disconnection in wiring 2) Disconnect connectors ATC3 and H.PS (CN19).
harness 3) Connect T-adapters to connectors ATC3 (female) and H.PS
3 (CN19) (female).
(Disconnection or
defective contact) Between ATC3 (female) (26) and H.PS Resis-
Max. 1 z
Between ATC3 (female) (3) and H.PS Resis-
Max. 1 z
troller
be performed.)
10 HD785-7
Table 1
Remedy against trouble

Speed when trouble
Failed clutch Action of controller ON/OFF state of
was detected
(Selected clutch, gear speed) lockup clutch
4th 4th OFF NEUTRAL OFF
F7
High High OFF NEUTRAL OFF
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
Reverse Reverse OFF NEUTRAL OFF
RH
RL
Low Low RH RH OFF
HD785-7 11
Failure code [DXH2KB] Hi clutch solenoid output circuit: Short circuit 1

Action code Failure code Hi clutch solenoid output circuit: Short circuit
Trouble
Contents of
trouble • Abnormally excessive current flows while output to Hi clutch ECMV solenoid is ON.
Action of
ure.
controller
Problem that
machine
• Electric current of output to ECMV solenoid can be checked by monitoring function (code: 31600
Related infor- (mA)).
mation k Raise the body at the highest position, and set damp lever to "Hold", and install body lock

1 Resis-
tance
Min. 1 Mz
ground tance
2
in wiring harness
Resis-
value in normal 2) Disconnect connectors ATC3 and H.PS (CN19).
state Ground fault in wiring har- 3) Connect T-adapter to ATC3 or H.PS (CN19) (female).
3
ness
Between ground and ATC3 (female) (26) or Resis-
Min. 1 Mz
H.PS (CN19) (female) (1) tance
not required.
Short circuit in wiring har- 2) Disconnect connectors ATC3 and H.PS (CN19).
4
ness 3) Connect T-adapter to ATC3 or H.PS (CN19) (female).
Min. 1 Mz
between H.PS (CN19) (female) (1) and (2) tance
troller
be performed.)
12 HD785-7
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
RH
RL
Low Low RH RH OFF
HD785-7 13
Failure code [DXH2KY] Hi clutch solenoid output circuit: Short circuit to

power supply line 1
Action code Failure code Hi clutch solenoid output circuit: Short circuit to power supply line
Trouble
Contents of
trouble • When output to Hi clutch ECMV solenoid is OFF, electric current flows.
Action of
ure.
controller
Problem that
machine

1 Resis-
tance
Min. 1 Mz
ground tance
3) Connect T-adapter to connector H.PS (CN19) (female) or insert
T-adapter into connector ATC3.
2
circuit is not present. (Hi clutch solenoid is defective.)
Between ground and ATC3 (26) or H.PS
Voltage Max. 1V
(CN19) (female) (1)
and standard 2) Disconnect connectors ATC3 and H.PS (CN19).
value in normal 3) Insert the T-adapter into connector ATC3.
ment.
2) Disconnect connectors ATC3, J05, TM3, and H.PS (CN19).
3
ment.
Between TM3 (male) (1) and each pin other No continuity
14 HD785-7

state troller
HD785-7 15
Table 2
Speed when trouble Failed clutch
was detected (Fill switch ON) Action of controller ON/OFF state of
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
F7 1st OFF NEUTRAL OFF
High
Reverse OFF NEUTRAL OFF
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
RH 2nd OFF NEUTRAL OFF
High
1st OFF NEUTRAL OFF
Low OFF NEUTRAL OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
RL 2nd OFF NEUTRAL OFF
Low
1st OFF NEUTRAL OFF
High RH RH OFF
N ANY NONE No reaction —
16 HD785-7
HD785-7 17
Failure code [DXH3KA] Lo clutch solenoid output circuit:

Disconnection 1
Action code Failure code Lo clutch solenoid output circuit: Disconnection
Trouble
Contents of
trouble • Current does not flow when output to Lo clutch ECMV solenoid is ON.
Action of
ure.
controller
Problem that
machine
• Electric current of output to ECMV solenoid can be checked with monitoring function (code: 31601
(mA)).
Related infor-
mation • Since output is turned ON and self-check is performed for 5 seconds after starting switch is turned
ON, wait for 5 seconds without starting the engine.

2) Disconnect connector L.PS (CN17).
3) Connect T-adapter to connector ATC3 (male).
Defective Lo clutch ECMV
1 Resis-
solenoid Between L.PS (CN17) (male) (1) and (2) 5 – 15 z
tance
Between L.PS (CN17) (male) (1) or (2) and Resis-
Min. 1 Mz
ground tance
2
in wiring harness
tance
value in normal
state
not required.
Disconnection in wiring 2) Disconnect connectors ATC3 and L.PS (CN17).
harness 3) Connect T-adapters to connectors ATC3 (female) and L.PS
3 (CN17) (female).
(Disconnection or defective
contact) Between ATC3 (female) (6) and L.PS Resis-
Max. 1 z
Between ATC3 (female) (13) and L.PS Resis-
Max. 1 z
troller
be performed.)
18 HD785-7
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
RH
RL
Low Low RH RH OFF
HD785-7 19
Failure code [DXH3KB] Lo clutch solenoid output circuit: Short circuit 1

Action code Failure code Lo clutch solenoid output circuit: Short circuit
Trouble
Contents of
trouble • Excessive current flows while output to Lo clutch ECMV solenoid is ON.
Action of
ure.
controller
Problem that
machine

3) Connect T-adapter to connector L.PS (CN17) (male).
1 Resis-
tance
Min. 1 Mz
ground tance
2
in wiring harness
Resis-
value in normal 2) Disconnect connectors ATC3 and L.PS (CN17).
state Ground fault in wiring of har- 3) Connect T-adapters to ATC3 or L.PS (CN17) (female).
3
ness
Min. 1 Mz
L.PS (CN17) (female) (1) tance
not required.
Short circuit in wiring har- 2) Disconnect connectors ATC3 and L.PS (CN17).
4
ness 3) Connect T-adapters to ATC3 or L.PS (CN17) (female).
Min. 1 Mz
between L.PS (CN17) (female) (1) and (2) tance
troller
be performed.)
20 HD785-7
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
RH
RL
Low Low RH RH OFF
HD785-7 21
Failure code [DXH3KY] Lo clutch solenoid output circuit: Short circuit

in power supply line 1
Action code Failure code Lo clutch solenoid output circuit: Short circuit to power supply line
Trouble
Contents of
trouble • When output to Lo clutch ECMV solenoid is turned “OFF“, current flows to circuit.
Action of
ure.
controller
Problem that
machine

3) Connect T-adapter to connector L.PS (CN17) (male).
1 Resis-
tance
Min. 1 Mz
ground tance
3) Connect T-adapter to connector L.PS (CN17) (female) or insert
2
circuit is not present. (Lo clutch solenoid is defective.)
Between ground and ATC3 (6) or L.PS
Voltage Max. 1 V
(CN17) (female) (1)
and standard 2) Disconnect connectors ATC3 and L.PS (CN17).
ment.
2) Disconnect connectors ATC3, J05, TM3, and L.PS (CN17).
3
ment.
Between TM3 (male) (4) and each pin other No continuity
22 HD785-7

state troller
HD785-7 23
Table 2
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
High
1st OFF NEUTRAL OFF
Low OFF NEUTRAL OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH RH OFF
24 HD785-7
HD785-7 25
Failure code [DXH4KA] 1st clutch solenoid output circuit:

Disconnection 1
Action code Failure code 1st clutch solenoid output circuit: Disconnection
Trouble
Contents of
trouble • Current does not flow when output to 1st clutch ECMV solenoid is ON.
Action of
ure.
controller
Problem that
machine
(mA)).
Related infor-

2) Disconnect connector 1.PS (CN6).
3) Connect T-adapter to connector 1.PS (CN6) (male).
Defective 1st clutch ECMV
1 Resis-
solenoid Between 1.PS (CN6) (male) (1) and (2) 5 – 15 z
tance
Between 1.PS (CN6) (male) (1) or (2) and Resis-
Min. 1 Mz
ground tance
Disconnection or short circuit 3) Connect T-adapter to ATC3 (female).
2
Possible causes in wiring harness
Resis-
value in normal tance
state a If no abnormality is found in check on cause 2, this check is
not required.
Disconnection in wiring 2) Disconnect connector ATC3 and 1.PS (CN6).
harness 3) Connect T-adapters to ATC3 (female) and 1.PS (CN6) (female).
3
(Disconnection or improper
Between ATC3 (female) (36) and 1.PS Resis-
contact) Max. 1 z
Between ATC3 (female) (3) and 1.PS (CN6) Resis-
Max. 1 z
(female) (2) tance
troller
be performed.)
26 HD785-7
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
RH
RL
Low Low RH RH OFF
HD785-7 27
Failure code [DXH4KB] 1st clutch solenoid output circuit: Short circuit1
Action code Failure code 1st clutch solenoid output circuit: Short circuit
Trouble
Contents of
trouble • Abnormally excessive current flows when output to 1st clutch ECMV solenoid is ON.
Action of
ure.
controller
Problem that
machine
Related infor- • Electric current of output to ECMV solenoid can be checked by monitoring function (code: 31602
mation (mA)).

1 Defective 1st clutch ECMV Resis-
Between 1.PS (CN6) (male) (1) and (2) 5 – 15 z
tance
Min. 1 Mz
ground tance
2
in wiring harness
Resis-
value in normal 2) Disconnect connectors ATC3 and 1.PS (CN6).
state Ground fault in wiring har- 3) Connect T-adapter to connector ATC3 or 1.PS (CN6) (female).
3
ness
Min. 1 Mz
1.PS (CN6) (female) (1) tance
not required.
Short circuit in wiring har- 2) Disconnect connectors ATC3 and 1.PS (CN6).
4
ness 3) Connect T-adapter to connector ATC3 or 1.PS (CN6) (female).
Min. 1 Mz
between 1.PS (CN6) (female) (1) and (2) tance
troller
be performed.)
28 HD785-7
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
RH
RL
Low Low RH RH OFF
HD785-7 29
Failure code [DXH4KY] 1st clutch solenoid output circuit: Short circuit
to power supply line 1
Action code Failure code 1st clutch solenoid output circuit: Short circuit to power supply line
Trouble
Contents of
trouble • When output to 1st clutch ECMV solenoid is "OFF", current flows to circuit.
Action of
ure.
controller
Problem that
machine

Defective 1st clutch ECMV
1 Resis-
tance
Min. 1 Mz
ground tance
3) Connect T-adapter to connector 1.PS (CN6) (female) or insert T-
adapter into connector ATC3.
2
circuit is not present. (1st clutch solenoid is defective.)
Between ground and ATC3 (female) (36) or
Voltage Max. 1 V
1.PS (CN6) (female) (1)
and standard 2) Disconnect connectors ATC3 and 1.PS (CN6).
value in normal 3) Connect the T-adapter into connector ATC3 (female).
ment.
2) Disconnect connector ATC3, J05, TM3, and 1.PS (CN6).
3
ment.
30 HD785-7

state troller
HD785-7 31
Table 2
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
High
1st OFF NEUTRAL OFF
Low OFF NEUTRAL OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH RH OFF
32 HD785-7
HD785-7 33
Failure code [DXH5KA] 2nd clutch solenoid output circuit:

Disconnection 1
Action code Failure code 2nd clutch solenoid output circuit: Disconnection
Trouble
Contents of
trouble • Current does not flow when output to 2nd clutch ECMV solenoid is ON.
Action of
ure.
controller
Problem that
machine
(mA)).
Related infor-

Defective 2nd clutch ECMV
1 Resis-
tance
Min. 1 Mz
ground tance
2
in wiring harness
tance
value in normal
state
not required.
Disconnection in wiring 2) Disconnect connectors ATC3 and 2.PS (CN8).
harness 3) Connect T-adapters to connectors ATC3 (female) and 2.PS
3 (CN8) (female).
contact) Between ATC3 (female) (5) and 2.PS (CN8) Resis-
Max. 1 z
(female) (1) tance
Max. 1 z
If no abnormality was found in the above troubleshooting, the
troller
34 HD785-7
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
RH
RL
Low Low RH RH OFF
HD785-7 35
Failure code [DXH5KB] 2nd clutch solenoid output circuit: Short circuit1
Action code Failure code 2nd clutch solenoid output circuit: Short circuit
Trouble
Contents of
trouble • Abnormally excessive current flows while output to 2nd clutch ECMV solenoid is ON.
Action of
ure.
controller
Problem that
machine

2) Disconnect connector 2.PS(CN8).
3) Connect T-adapter to connector 2.PS(CN8) (male).
1 Resis-
tance
Min. 1 Mz
ground tance
2
in wiring harness
Resis-
state Ground fault in wiring har- 3) Connect T-adapters to ATC3 (female) or 2.PS (CN8).
3
ness
Min. 1 Mz
not required.
4
ness 3) Connect T-adapters to ATC3 (female) or 2.PS (CN8).
Min. 1 Mz
troller
36 HD785-7
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
RH
RL
Low Low RH RH OFF
HD785-7 37
Failure code [DXH5KY] 2nd clutch solenoid output circuit: Short circuit
in power supply line 1
Action code Failure code 2nd clutch solenoid output circuit: Short circuit in power supply line
Trouble
Contents of
trouble • When output to 2nd clutch ECMV solenoid is "OFF", current flows to circuit.
Action of
ure.
controller
Problem that
machine

2) Disconnect connector 2.PS(CN8).
3) Connect T-adapter to connector 2.PS(CN8) (male).
1 Resis-
solenoid Between 2.PS(CN8) (male) (1) and (2) 5 – 15 z
tance
Between 2.PS(CN8) (male) (1) or (2) and Resis-
Min. 1 Mz
ground tance
3) Connect T-adapter to connector 2.PS (CN8) (female) or insert T-
adapter into connector ATC3.
2
(Contact with 24V circuit) a If failure code [DXH5KA] for disconnection appears, hot short
circuit is not present. (2nd clutch solenoid is defective.)
Between ground and ATC3 (5) or 2.PS(CN8)
Voltage Max. 1 V
(female) (1)
ment.
2) Disconnect connectors ATC3, J05, TM3, and 2.PS (CN8).
3
ment.
38 HD785-7

state troller
HD785-7 39
Table 2
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
High
1st OFF NEUTRAL OFF
Low OFF NEUTRAL OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH RH OFF
40 HD785-7
HD785-7 41
Failure code [DXH6KA] 3rd clutch solenoid output circuit:

Disconnection 1
Action code Failure code 3rd clutch solenoid output circuit: Disconnection
Trouble
Contents of
trouble • Current does not flow when output to 3rd clutch ECMV solenoid is ON.
Action of
ure.
controller
Problem that
machine
(mA)).
Related infor-

Defective 3rd clutch ECMV
1 Resis-
tance
Min. 1 Mz
ground tance
2) Disconnect connectors ATC3 and 3.PS (CN10).
2
in wiring harness
tance
value in normal
state
not required.
Disconnection in wiring 2) Disconnect connectors ATC3 and 3.PS (CN10).
harness 3) Connect T-adapters to connectors ATC3 (female) and 3.PS
3 (CN10) (female).
contact) Between ATC3 (female) (15) and 3.PS Resis-
Max. 1 z
Max. 1 z
troller
42 HD785-7
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
RH
RL
Low Low RH RH OFF
HD785-7 43
Failure code [DXH6KB] 3rd clutch solenoid output circuit: Short circuit1
Action code Failure code 3rd clutch solenoid output circuit: Short circuit
Trouble
Contents of
trouble • Abnormally excessive current flows while output to 3rd clutch ECMV solenoid is ON.
Action of
ure.
controller
Problem that
machine

1 Resis-
tance
Min. 1 Mz
ground tance
2
in wiring harness
Resis-
state Ground fault in wiring har- 3) Connect T-adapter to ATC3 or 3.PS (CN10) (female).
3
ness
Min. 1 Mz
not required.
4
ness 3) Connect T-adapter to ATC3 or 3.PS (CN10) (female).
Min. 1 Mz
troller
44 HD785-7
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
RH
RL
Low Low RH RH OFF
HD785-7 45
Failure code [DXH6KY] 3rd clutch solenoid output circuit: Short circuit
to power supply line 1
Action code Failure code 3rd clutch solenoid output circuit: Short circuit to power supply line
Trouble
Contents of
trouble • When output to 3rd clutch ECMV solenoid is OFF, current flows to circuit.
Action of
ure.
controller
Problem that
machine

1 Resis-
tance
Min. 1 Mz
ground tance
3) Connect T-adapter to connector 3.PS (CN10) (female) or insert
2
circuit is not present. (3rd clutch solenoid is defective.)
Between ground and ATC3 (15) or 3.PS
Voltage Max. 1 V
(CN10) (female) (1)
state a Use the continuity range of the multimeter for the mea-
surement.
2) Disconnect connectors ATC3, J05, TM3, and 3.PS (CN10).
3
ness a Use the continuity range of the multimeter for the mea-
surement.
46 HD785-7

state troller
HD785-7 47
Table 2
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
High
1st OFF NEUTRAL OFF
Low OFF NEUTRAL OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH RH OFF
48 HD785-7
HD785-7 49

HD785-7 SEN01274-15 Shop Manual-1206-1406

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40 Troubleshooting SEN01944-02

Circuit diagram related

HD785-7 Dump truck

DUMP TRUCK 1SHOP MANUAL

Machine model Serial number

Failure code [DLF6KA] Disconnection in wheel speed sensor (Front

Cause Standard value in normal state/Remarks on troubleshooting

Circuit diagram related

Failure code [DLF6L3] Trouble in wheel speed sensor (Front right) 1

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

Failure code [DLF7KA] Disconnection in wheel speed sensor (Front left)1

Cause Standard value in normal state/Remarks on troubleshooting

Circuit diagram related

Failure code [DLF7L3] Trouble in wheel speed sensor (Front left) 1

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

Failure code [DLF8KA] Wheel speed sensor: Disconnection (Rear

Cause Standard value in normal state/Remarks on troubleshooting

Circuit diagram related

Failure code [DLF8L3] Wheel speed sensor: Disconnection (Rear right)1

Cause Standard value in normal state/Remarks on troubleshooting

Circuit diagram related

Failure code [DLF8LC] Wheel speed sensor: Trouble (Rear right) 1

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

Failure code [DLF8MA] Wheel speed sensor: Disconnection (Rear right)1

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

Failure code [DLF9KA] Wheel speed sensor: Disconnection (Rear left) 1

Cause Standard value in normal state/Remarks on troubleshooting

Circuit diagram related

Failure code [DLF9L3] Wheel speed sensor: Trouble (Rear left) 1

Cause Standard value in normal state/Remarks on troubleshooting

Circuit diagram related

Failure code [DLF9LC] Wheel speed sensor: Trouble (Rear left) 1

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

Failure code [DLF9MA] Wheel speed sensor: Disconnection (Rear left) 1

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

Failure code [DLT3KA] Transmission output shaft speed sensor:

Cause Standard value in normal state/Remarks on troubleshooting

Circuit diagram related

Failure code [DLT3LC] Transmission output shaft speed sensor:

Cause Standard value in normal state/Remarks on troubleshooting

Circuit diagram related

Failure code [DLT4KA] Transmission output shaft speed sensor:

Cause Standard value in normal state/Remarks on troubleshooting

Circuit diagram related

Failure code [DLT4MA] Transmission output shaft speed sensor:

Cause Standard value in normal state/Remarks on troubleshooting

Cause Standard value in normal state/Remarks on troubleshooting

Circuit diagram related

Failure code [DUM7KY] Pre-lubrication operation lamp output

Cause Standard value in normal state/Remarks on troubleshooting

Related electrical circuit diagram

a Prelube controller is the same as pre-lubrication controller.

Failure code [DUM7KZ] Pre-lubrication operation lamp output

Cause Standard value in normal state/Remarks on troubleshooting

Related electrical circuit diagram

a Prelube controller is the same as pre-lubrication controller.

Failure code [DV00KB] Buzzer output: Short circuit 1

Cause Standard value in normal state/Remarks on troubleshooting

Circuit diagram related