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Komatsu GD510, GD520 Series Shop Manual SEBMG5250107 – PDF DOWNLOAD
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Komatsu GD510, GD520 Series Shop Manual
MACHINE MODEL SERIAL NO.
- GD521A-1 10001 and up
- GDSZZA-1 20001 and up
- G0523A-1 30001 and up
- GDSZSA-1 50001 and up
- GDS11A-1 10001 and up
- GD513A-1 30001 and up
- GD521R-1 10001 and up
- GD523R-1 30001 and up
- GDS11R-1 10001 and up
- GD513R-1 30001 and up
- GD510R-1 15001 and up
- GDS15A-1 50001 and up
- GDSZSA-1C 60001 and up
- GDSZSA-1A 50001 and up
- GDSZSA-1B 55001 and up
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Description
Komatsu GD510, GD520 Series Shop Manual SEBMG5250107
FILE DETAILS:
Komatsu GD510, GD520 Series Shop Manual
Brands: Komatsu
Equipment Type: Shop Manual
Manuals Type: Shop Manual
Machine Model: GD510,GD520 Series
Serial Number: 10001 and up, 20001 and up, 30001 and up, 50001 and up, 15001 and up, 60001 and up, 55001 and up
Book Code: SEBMG5250107
Language: English
Pages: 650
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu GD510, GD520 Series Shop Manual
FOREWORD:
GENERAL:
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD:
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu GD510, GD520 Series Shop Manual
COVER...................................................................................................................................................................................... 1 CONTENTS................................................................................................................................................................................... 2 10 ENGINE.................................................................................................................................................................................. 25 12 TESTING AND ADJUSTING............................................................................................................................................................... 26 TABLE OF JUDGEMENT STANDARD VALUE.................................................................................................................................................. 27 TESTING AND ADJUSTING TOOL LIST.................................................................................................................................................... 31 ADJUSTING VALVE CLEARANCE.......................................................................................................................................................... 32 MEASURING COMPRESSION PRESSURE..................................................................................................................................................... 34 TESTING AND ADJUSTING FUEL INJECTION TIMING........................................................................................................................................ 36 BLEEDING AIR-FROM FUEL SYSTEM...................................................................................................................................................... 39 ENGINE SPEED CONTROL............................................................................................................................................................... 40 13 DISASSEMBLY AND ASSEMBLY............................................................................................................................................................ 41 RADIATOR........................................................................................................................................................................... 42 REMOVAL........................................................................................................................................................................ 42 INSTALLATION................................................................................................................................................................... 42 RADIATOR ASSEMBLY.................................................................................................................................................................. 44 REMOVAL........................................................................................................................................................................ 44 INSTALLATION................................................................................................................................................................... 44 FUEL TANK(INCL.HYDRAULIC TANK)ASSEMBLY............................................................................................................................................. 46 REMOVAL........................................................................................................................................................................ 46 INSTALLATION................................................................................................................................................................... 48 20 POWER TRAIN............................................................................................................................................................................. 54 21 STRUCTURE AND FUNCTION.............................................................................................................................................................. 55 GENERAL............................................................................................................................................................................ 56 POWER TRAIN........................................................................................................................................................................ 57 HYDROSHIFT TRANSMISSION PIPING..................................................................................................................................................... 59 HYDROSHIFT TRANSMISSION CONTROL.................................................................................................................................................... 60 POWER TRAIN HYDRAULIC CIRCUIT SCHEMATICS........................................................................................................................................... 61 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM.............................................................................................................................................. 62 PTO................................................................................................................................................................................ 63 HYDROSHIFT TRANSMISSION............................................................................................................................................................ 65 TRANSFER........................................................................................................................................................................... 70 TRANSMISSION CONTROL VALVE......................................................................................................................................................... 72 POWER TRAIN.................................................................................................................................................................... 80 MAIN CLUTCH.................................................................................................................................................................... 81 TRANSMISSION................................................................................................................................................................... 82 HYDROSHIFT TRANSMISSION PUMP....................................................................................................................................................... 84 FINAL DRIVE........................................................................................................................................................................ 86 FINAL DRIVE,DIFFERENTIAL LOCK AND UNLOCK PIPING.................................................................................................................................... 94 TANDEM DRIVE....................................................................................................................................................................... 96 22 TESTING ADJUSTING................................................................................................................................................................... 98 TABLE OF JUDGEMENT STANDARD VALUE.................................................................................................................................................. 99 TOOL LIST FOR TESTING AND ADJUSTING................................................................................................................................................100 INCHING PEDAL TRAVEL AND OPERATING FORCE...........................................................................................................................................101 MAIN CLUTCH........................................................................................................................................................................103 TRANSMISSION CONTROL LEVER TRAVEL AND OPERATING FORCE..............................................................................................................................106 CHECKING OIL PRESSURE..............................................................................................................................................................107 MACHINE TYPE AND INCHING PRESSURE..................................................................................................................................................109 TRANSMISSION CONTROL LEVER TRAVEL AND OPERATING FORCE..............................................................................................................................110 CLEARANCE DIFFERENTIAL LOCKING DEVICE OIL PRESSURE.................................................................................................................................111 23 DISASSEMBLY AND ASSEMBLY............................................................................................................................................................112 ENGINE(INCL.TRANSMISSION)ASSEMBLY..................................................................................................................................................113 REMOVAL........................................................................................................................................................................113 INSTALLATION...................................................................................................................................................................117 MAIN CLUTCH ASSEMBLY...............................................................................................................................................................135 REMOVAL........................................................................................................................................................................135 INSTALLATION...................................................................................................................................................................135 MAIN CLUTCH CASE ASSEMBLY..........................................................................................................................................................137 DISASSEMBLY....................................................................................................................................................................137 ASSEMBLY.......................................................................................................................................................................137 MAIN CLUTCH ASSEMBLY...............................................................................................................................................................139 DISASSEMBLY....................................................................................................................................................................139 ASSEMBLY.......................................................................................................................................................................139 MAIN CLUTCH BOOSTER ASSEMBLY.......................................................................................................................................................141 DISASSEMBLY....................................................................................................................................................................141 ASSEMBLY.......................................................................................................................................................................141 TRANSMISSION ASSEMBLY..............................................................................................................................................................143 REMOVAL........................................................................................................................................................................143 INSTALLATION...................................................................................................................................................................147 DISASSEMBLY....................................................................................................................................................................151 ASSEMBLY.......................................................................................................................................................................157 SHIFTING FORK COVER ASSEMBLY.......................................................................................................................................................163 DISASSEMBLY....................................................................................................................................................................163 ASSEMBLY.......................................................................................................................................................................163 TRANSMISSION.......................................................................................................................................................................165 DISASSEMBLY....................................................................................................................................................................165 ASSEMBLY.......................................................................................................................................................................178 LOW SPEED ROTATING CLUTCH..........................................................................................................................................................194 DISASSEMBLY....................................................................................................................................................................194 ASSEMBLY.......................................................................................................................................................................197 INTERMEDIATE SHAFT ROTATING CLUTCH.................................................................................................................................................200 DISASSEMBLY....................................................................................................................................................................200 ASSEMBLY.......................................................................................................................................................................203 CAGE AND CARRIER...................................................................................................................................................................206 DISASSEMBLY....................................................................................................................................................................206 ASSEMBLY.......................................................................................................................................................................207 TRANSMISSION CASE..................................................................................................................................................................208 DISASSEMBLY....................................................................................................................................................................208 ASSEMBLY.......................................................................................................................................................................209 PLANETARY GEAR.....................................................................................................................................................................210 DISASSEMBLY....................................................................................................................................................................210 ASSEMBLY.......................................................................................................................................................................210 TRANSMISSION PUMP..................................................................................................................................................................211 REMOVAL........................................................................................................................................................................211 INSTALLATION...................................................................................................................................................................211 TANDEM AND FINAL DRIVE.............................................................................................................................................................215 REMOVAL........................................................................................................................................................................215 INSTALLATION...................................................................................................................................................................215 TANDEM,FINAL DRIVE ASSEMBLY........................................................................................................................................................217 REMOVAL........................................................................................................................................................................217 INSTALLATION...................................................................................................................................................................217 FINAL DRIVE........................................................................................................................................................................221 DISASSEMBLY....................................................................................................................................................................221 ASSEMBLY.......................................................................................................................................................................225 TANDEM,FINAL DRIVE ASSEMBLY........................................................................................................................................................231 DISASSEMBLY....................................................................................................................................................................231 ASSEMBLY.......................................................................................................................................................................235 SIDE CASE ASSEMBLY.................................................................................................................................................................243 DISASSEMBLY....................................................................................................................................................................243 ASSEMBLY.......................................................................................................................................................................243 BEVEL GEAR ASSEMBLY................................................................................................................................................................245 DISASSEMBLY....................................................................................................................................................................245 ASSEMBLY.......................................................................................................................................................................245 PINION ASSEMBLY....................................................................................................................................................................255 DISASSEMBLY....................................................................................................................................................................255 ASSEMBLY.......................................................................................................................................................................255 24 MAINTENANCE STANDARD................................................................................................................................................................257 PTO................................................................................................................................................................................258 MAIN CLUTCH........................................................................................................................................................................262 TRANSMISSION.......................................................................................................................................................................265 HYDROSHIFT TRANSMISSION............................................................................................................................................................266 TRANSFER...........................................................................................................................................................................270 HYDROSHIFT TRANSMISSION CONTROL VALVE..............................................................................................................................................272 TRANSMISSION PUMP..................................................................................................................................................................277 FINAL DRIVE........................................................................................................................................................................279 TANDEM DRIVE.......................................................................................................................................................................283 40 STEERING SYSTEM.........................................................................................................................................................................284 41 STRUCTURE AND FUNCTION..............................................................................................................................................................285 STEERING PIPING....................................................................................................................................................................286 STEERING CIRCUIT DIAGRAM...........................................................................................................................................................287 STEERING CONTROL VALVE.............................................................................................................................................................288 FRONT AXLE.........................................................................................................................................................................293 STEERING CYLINDER..................................................................................................................................................................298 WHEEL..............................................................................................................................................................................299 42 TESTING AND ADJUSTING...............................................................................................................................................................303 TABLE OF JUDGEMENT STANDARD........................................................................................................................................................304 TOOL LIST FOR TESTING AND ADJUSTING................................................................................................................................................305 CHECKING STEERING WHEEL............................................................................................................................................................306 CHECKING TIRE RUNOUT...............................................................................................................................................................307 CHECKING TIRE INFLATION PRESSURE...................................................................................................................................................307 CHECKING TOE-IN....................................................................................................................................................................308 43 DISASSEMBLY AND ASSEMBLY............................................................................................................................................................309 FRONT AXLE ASSEMBLY................................................................................................................................................................310 REMOVAL........................................................................................................................................................................310 INSTALLATION...................................................................................................................................................................310 FRONT AXLE ASSEMBLY................................................................................................................................................................312 DISASSEMBLY....................................................................................................................................................................312 ASSEMBLY.......................................................................................................................................................................318 STEERING VALVE.....................................................................................................................................................................324 DISASSEMBLY....................................................................................................................................................................324 ASSEMBLY.......................................................................................................................................................................328 DOUBLE RELIEF VALVE................................................................................................................................................................332 DISASSEMBLY....................................................................................................................................................................332 ASSEMBLY.......................................................................................................................................................................332 44 MAINTENANCE STANDARD................................................................................................................................................................334 FRONT AXLE.........................................................................................................................................................................335 STEERING CYLINDER..................................................................................................................................................................339 50 BRAKE SYSTEM............................................................................................................................................................................340 51 STRUCTURE AND FUNCTION..............................................................................................................................................................341 BRAKE PIPING.......................................................................................................................................................................342 BRAKE CIRCUIT DIAGRAM..............................................................................................................................................................343 BOOST MASTER.......................................................................................................................................................................344 BRAKE AIR PIPING...................................................................................................................................................................347 AIR BRAKE CIRCUIT SCHEMATICS.......................................................................................................................................................348 AIR BRAKE CIRCUIT DIAGRAM..........................................................................................................................................................349 BRAKE VALVE........................................................................................................................................................................350 AIR COMPRESSOR.....................................................................................................................................................................354 AIR GOVERNOR.......................................................................................................................................................................355 CHECK VALVE........................................................................................................................................................................356 AIR TANK...........................................................................................................................................................................357 SAFETY VALVE.......................................................................................................................................................................357 AUTOMATIC DRAIN VALVE..............................................................................................................................................................358 AIR DRIER..........................................................................................................................................................................360 WHEEL BRAKE........................................................................................................................................................................362 PARKING BRAKE......................................................................................................................................................................365 52 TESTING AND ADJUSTING...............................................................................................................................................................367 TABLE OF JUDGEMENT STANDARD VALUE..................................................................................................................................................368 TOOL LIST FOR TESTING AND ADJUSTING................................................................................................................................................368 CHECKING BRAKE PEDAL...............................................................................................................................................................369 AIR BLEEDING FROM BRAKE CIRCUIT....................................................................................................................................................371 CHECKING PARKING BRAKE LEVER.......................................................................................................................................................372 CHECKING WEAR OF BRAKE DISC........................................................................................................................................................373 53 DISASSEMBLY AND ASSEMBLY............................................................................................................................................................374 WHEEL BRAKE........................................................................................................................................................................375 REMOVAL........................................................................................................................................................................375 INSTALLATION...................................................................................................................................................................375 WHEEL BRAKE ASSEMBLY...............................................................................................................................................................377 REMOVAL........................................................................................................................................................................377 INSTALLATION...................................................................................................................................................................377 DISASSEMBLY....................................................................................................................................................................381 ASSEMBLY.......................................................................................................................................................................385 BOOST MASTER.......................................................................................................................................................................391 DISASSEMBLY....................................................................................................................................................................391 ASSEMBLY.......................................................................................................................................................................393 PARKING BRAKE......................................................................................................................................................................395 REMOVAL AND DISASSEMBLY........................................................................................................................................................395 INSTALLATION AND ASSEMBLY......................................................................................................................................................395 54 MAINTENANCE STANDARD................................................................................................................................................................398 WHEEL BRAKE........................................................................................................................................................................399 PARKING BRAKE......................................................................................................................................................................401 BOOST MASTER.......................................................................................................................................................................403 60 HYDRAULIC SYSTEM........................................................................................................................................................................404 61 STRUCTURE AND FUNCTION..............................................................................................................................................................405 HYDRAULIC CONTROL PIPING...........................................................................................................................................................406 HYDRAULIC CONTROL LINKAGE..........................................................................................................................................................417 BLADE ACCUMULATOR SYSTEM ..........................................................................................................................................................419 HYDRAULIC CIRCUIT DIAGRAM..........................................................................................................................................................421 FLOW DIVIDER.......................................................................................................................................................................424 HYDRAULIC PUMP.....................................................................................................................................................................425 CIRCLE ROTATION MOTOR..............................................................................................................................................................427 WORK EQUIPMENT CONTROL VALVE.......................................................................................................................................................433 PILOT CHECK VALVE..................................................................................................................................................................440 HYDRAULIC CYLINDER.................................................................................................................................................................444 63 DISASSEMBLY AND ASSEMBLY............................................................................................................................................................447 HYDRAULIC PUMP(INCL.STEERING PUMP).................................................................................................................................................448 REMOVAL........................................................................................................................................................................448 INSTALLATION...................................................................................................................................................................448 BLADE LIFT CYLINDER................................................................................................................................................................450 REMOVAL........................................................................................................................................................................450 INSTALLATION...................................................................................................................................................................450 DRAWBAR SHIFT CYLINDER.............................................................................................................................................................452 REMOVAL........................................................................................................................................................................452 INSTALLATION...................................................................................................................................................................452 ARTICULATE CYLINDER................................................................................................................................................................452 REMOVAL........................................................................................................................................................................452 INSTALLATION...................................................................................................................................................................452 BLADE SIDE SHIFT CYLINDER..........................................................................................................................................................454 REMOVAL........................................................................................................................................................................454 INSTALLATION...................................................................................................................................................................454 BLADE SIDE SHIFT CYLINDER ASSEMBLY.................................................................................................................................................456 REMOVAL........................................................................................................................................................................456 INSTALLATION...................................................................................................................................................................456 SCARIFIER CYLINDER ASSEMBLY........................................................................................................................................................458 REMOVAL........................................................................................................................................................................458 INSTALLATION...................................................................................................................................................................458 LEANING CYLINDER...................................................................................................................................................................458 REMOVAL........................................................................................................................................................................458 INSTALLATION...................................................................................................................................................................458 POWER TILT CYLINDER................................................................................................................................................................460 REMOVAL........................................................................................................................................................................460 INSTALLATION...................................................................................................................................................................460 REAR MOUNT RIPPER CYLINDER ASSEMBLY................................................................................................................................................460 REMOVAL........................................................................................................................................................................460 INSTALLTION....................................................................................................................................................................460 HYDRAULIC CYLINDER ASSEMBLY........................................................................................................................................................462 DISASSEMBLY....................................................................................................................................................................462 ASSEMBLY.......................................................................................................................................................................466 CIRCLE ROTATION MOTOR..............................................................................................................................................................474 DISASSEMBLY....................................................................................................................................................................474 ASSEMBLY.......................................................................................................................................................................480 64 MAINTENANCE STANDARD................................................................................................................................................................494 HYDRAULIC PUMP.....................................................................................................................................................................495 HYDRAULIC CONTROL VALVE............................................................................................................................................................497 HYDRAULIC CYLINDER.................................................................................................................................................................501 70 WORK EQUIPMENT..........................................................................................................................................................................507 71 STRUCTURE AND FUNCTION..............................................................................................................................................................508 DRAWBAR AND LIFTER.................................................................................................................................................................509 BLADE..............................................................................................................................................................................513 CIRCLE ROTATION GEAR...............................................................................................................................................................517 SCARIFIER..........................................................................................................................................................................518 REAR MOUNT RIPPER..................................................................................................................................................................519 FRAME..............................................................................................................................................................................520 72 TESTING AND ADJUSTING...............................................................................................................................................................522 TABLE OF JUDGEMENT STANDARD VALUE..................................................................................................................................................523 TOOL LIST FOR TESTING AND ADJUSTING................................................................................................................................................527 CHECKING CONTROL LEVER.............................................................................................................................................................528 CHECKING HYDRAULIC OIL TRMPERATURE.................................................................................................................................................529 CHECKING HYDRAULIC OIL PRESSURE....................................................................................................................................................529 HYDRAULIC DRIFT....................................................................................................................................................................531 CHARGING BLADE ACCUMULATOR WITH GAS................................................................................................................................................532 ADJUSTMENT OF CIRCLE GUIDE.........................................................................................................................................................533 73 DISASSEMBLY AND ASSEMBLY............................................................................................................................................................534 BLADE ASSEMBLY.....................................................................................................................................................................535 REMOVAL........................................................................................................................................................................535 INSTALLTION....................................................................................................................................................................535 CIRCLE ROTATION GEAR...............................................................................................................................................................537 REMOVAL........................................................................................................................................................................537 INSTALLATOIN...................................................................................................................................................................537 DISASSEMBLY....................................................................................................................................................................539 ASSEMBLY.......................................................................................................................................................................541 REAR MOUNT RIPPER ASSEMBLY.........................................................................................................................................................543 REMOVAL........................................................................................................................................................................543 INSTALLATION...................................................................................................................................................................543 74 MAINTENANCE STANDARD................................................................................................................................................................545 DRAWBAR AND LIFTER.................................................................................................................................................................546 BLADE..............................................................................................................................................................................550 CIRCLE ROTATION GEAR...............................................................................................................................................................551 SCARIFIER..........................................................................................................................................................................552 REAR MOUNT RIPPER..................................................................................................................................................................553 80 ELECTRIC AND ELECTRONIC SYSTEM..........................................................................................................................................................554 81 STRUCTURE AND FUNCTION..............................................................................................................................................................555 ELECTRICAL CIRCUIT DIAGRAM.........................................................................................................................................................556 CIRCUIT DIAGRAM OF CAB.............................................................................................................................................................560 ELECTRONIC VEHICLE MONITORING SYSTEM(EVMS).........................................................................................................................................562 ADJUSTING SPEEDOMETER MODULE OF MACHINE MONITOR....................................................................................................................................567 82 TESTING AND ADJUSTING...............................................................................................................................................................572 TABLE OF MONITOR REFERENCE VALUES..................................................................................................................................................573 ELECTRICAL WIRING DIAGRAM..........................................................................................................................................................576 POSITION OF CONNECTOR..............................................................................................................................................................578 CONNECTOR TERMINAL NUMBER..........................................................................................................................................................586 PRECAUTION WHEN HANDLING CONNECTOR.................................................................................................................................................591 METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART..................................................................................................................................593 TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM (D TYPE) (M-1 TO M-18)..............................................................................................594 M-1 WHEN STARTING SWITCH IS TURNED ON,MONITOR PANEL DISPLAY DOES NOT APPEAR....................................................................................................595 a) NONE OF MONITOR PANEL WORKS.............................................................................................................................................595 b) PART OF MONITOR PANEL DOES NOT WORK.....................................................................................................................................595 M-2 WHEN STARTING SWITCH IS TURNED ON,MONITOR PANEL DISPLAY DOES NOT GO OUT....................................................................................................595 a) MONITOR MODULE DOES NOT GO OUT .........................................................................................................................................595 b) GAUGE MODULE DOES NOT GO OUT ...........................................................................................................................................595 c) SPEEDOMETER MODULE DOES NOT GO OUT .....................................................................................................................................595 M-3 WHEN STARTING SWITCH IS TURNED ON,(DO NOT START ENGINE),CHECK BEFORE STARTING ITEMS FLASH OR PREHEATING ITEM LIGHTS UP.....................................................596 a) COOLANT LEVEL...........................................................................................................................................................596 b) ENGINE OIL LEVEL........................................................................................................................................................596 c) PREHEATER...............................................................................................................................................................597 M-4 WHEN STARTING SWITCH IS TURNED ON,(ENGINE STARTED),CHECK BEFORE STARTING ITEMS FLASH.......................................................................................598 a) ALTERNATOR SYSTEM.......................................................................................................................................................598 b) ENGINE OIL PRESSURE CIRCUIT.............................................................................................................................................598 M-5 WHEN STARTING SWITCH IS TURNED ON,(DO NOT START ENGINE),CAUTION ITEMS FLASH................................................................................................599 M-6 WHEN STARTING SWITCH IS ON(ENGINE STARTED),CAUTION ITEMS FLASH.............................................................................................................600 a) ENGINE OIL PRESSURE.....................................................................................................................................................600 b) COOLANT LEVEL...........................................................................................................................................................600 c) COOLANT TEMPERATURE.....................................................................................................................................................601 d) BATTERY CHARGE..........................................................................................................................................................601 e) FINAL OIL TEMPERATURE...................................................................................................................................................602 f) AIR PRESSURE............................................................................................................................................................602 g) PARKING BRAKE...........................................................................................................................................................603 M-7 FUEL TANK IS NOT FULL BUT DISPLAY SHOWS FULL TANK..........................................................................................................................604 M-8 NO DISPLAY IS GIVEN FOR FUEL LEVEL.........................................................................................................................................604 M-9 ENGINE COOLANT TEMPERATURE IS HIGH,BUT LOWEST LEVEL DISPLAYED..............................................................................................................605 M-10 ENGINE COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY .......................................................................................................................605 M-11 TURN SIGNAL LAMPS,HIGH BEAM LIGHT UP ABNORMALLY,OR DO NOT LIGHT UP........................................................................................................606 a) PILOT DISPLAY OF TURN SIGNAL LAMP (RIGHT) LIGHT UP......................................................................................................................606 b) PILOT DISPLAY OF TURN SIGNAL LAMP (LEFT) LIGHT UP.......................................................................................................................606 c) PILOT DISPLAY OF TURN SIGNAL LAMP (RIGHT) DOES NOT LIGHTS UP............................................................................................................606 d) PILOT DISPLAY OF TURN SIGNAL LAMP (LEFT) DOES NOT LIGHTS UP.............................................................................................................607 e) HIGH BEAM PILOT LAMP DOES NOT LIGHT UP..................................................................................................................................607 f) HIGH BEAM PILOT LAMP DOES NOT GO OUT ...................................................................................................................................607 M-12 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY................................................................................................................................608 M-13 WHEN ENGINE IS STARTED,SERVICE METER DOES NOT MOVE.WHEN ENGINE IS STOOPED,SERVICE METER MOVES.............................................................................609 a) SERVICE METER DOES NOT MOVE.............................................................................................................................................609 b) SERVICE METER DOES NOT STOP MOVING......................................................................................................................................609 M-14 MONITOR PANEL LAMPS DO NOT LIGHT UP.......................................................................................................................................610 a) NO LAMPS ON PANEL LIGHT UP..............................................................................................................................................610 b) SOME LAMPS ON PANEL DO NOT LIGHT UP.....................................................................................................................................610 M-15 CENTRAL WARNING LAMP DOES NOT GO OUT......................................................................................................................................611 a) MONITOR DISPLAYS NO ABNORMALITY,BUT CENTRAL WARNING LAMP LIGHTS UP INTERMITTENTLY.......................................................................................611 b) CENTRAL WARNING LAMP LIGHTS UP CONTINUOUSLY.............................................................................................................................611 M-16 CENTRAL WARNING BUZZER DOES NOT STOP......................................................................................................................................612 a) MONITOR DISPLAYS NO ABNORMALITY,BUT CENTRAL WARNING BUZZER SOUNDS INTERMITTENTLY........................................................................................612 b) CENTRAL WARNING BUZZER SOUNDS CONTINUOUSLY..............................................................................................................................612 M-17 EMERGENCY ITEM OR NON-EMERGENCY ITEMS IS FLASHING,BUT WARNING LAMP DOES NOT FLASH.........................................................................................613 M-18 EMERGENCY ITEM IS FLASHING,BUT ALARM BUZZER DOES NOT SOUND................................................................................................................614 TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM(M,N TYPE) (M-1 TO M-22).............................................................................................622 M-1 MONITOR PANEL PILOT LAMPS DO NOT LIGHT UP FOT 3 SECONDS WHEN STARTING SWITCH IS TURNED ON..................................................................................623 a) NO LAMPS ON MONITOR PANEL (MONITOR MODULE) LIGHT UP.....................................................................................................................623 b) NO LAMPS ON MONITOR PANEL (SPEEDOMETER MODULE) LIGHT UP.................................................................................................................623 c) SOME LAMPS ON MONITOR PANEL DO NOT LIGHT UP.............................................................................................................................623 M-2 WHEN STARTING SWITCH IS TURNED ON,ALL MONITOR PANEL LAMPS LIGHT UP BUT DO NOT GO OUT.......................................................................................623 M-3 WHEN STARTING SWITCH IS TURNED ON (WITH ENGINE STOPPED),CHECK ITEMS FLASH..................................................................................................625 a) RADIATOR WATER LEVEL FLASHES............................................................................................................................................625 b) ENGINE OIL LEVEL FLASHES................................................................................................................................................626 M-4 PREHEATING IS NOT BEING CARRIED OUT,BUT PREHEATING DISPLAY FLASHES.........................................................................................................627 M-5 WHEN STARTING SWTICH IS TURNED ON AND ENGINE IS STARTED,CHECK ITEMS FLASH..................................................................................................628 a) ALTERNATOR SYSTEM.......................................................................................................................................................628 b) ENGINE OIL PRESSURE SYSTEM..............................................................................................................................................629 M-6 WHEN STARTING SWITCH IS TURNED ON (WITH ENGINE STOPPED),CAUTION ITEMS FLASH................................................................................................630 M-7 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED,CAUTION ITEMS FLASH................................................................................................632 a) ENGINE OIL PRESSURE FLASHES.............................................................................................................................................632 b) RADIATOR WATER LEVEL FLASHES............................................................................................................................................633 c) ENGINE WATER TEMPERATURE FLASHES........................................................................................................................................633 d) CHARGE FLASHES..........................................................................................................................................................634 e) FINAL DRIVE OIL TEMPERATURE FLASHES.....................................................................................................................................635 f) AIR PRESSURE FLASHES....................................................................................................................................................636 g) PARKING BRAKE FLASHES...................................................................................................................................................637 M-8 FOR ONE SECOND AFTER STARTING SWITCH IS TURNED ON (ENGINE STOPPED),ALARM BUZZER DOES NOT SOUND.CAUTION ITEM LAMPS ARE FLASHING BUT ALARM BUZZER DOES NOT SOUND.............638 M-9 THERE IS NO ABNORMALITY ON MONITOR DISPLAY,BUT ALARM BUZZER SOUNDS.........................................................................................................638 M-10 FOR TWO SECONDS AFTER STARTING SWITCH IS TURNED ON (ENGINE STOPPED),WARNING LAMP DOES NOT LIGHT UP.CAUTION ITEM LAMPS ARE FLASHING BUT WARNING LAMP DOES NOT LIGHT UP.....639 M-11 THERE IS NO ABNORMALITY ON MONITOR DISPLAY,BUT WARNING LAMP LIGHTS UP.....................................................................................................639 M-12 MONITOR PANEL LIGHTING DOES NOT LIGHT UP..................................................................................................................................641 a) NO PANEL LIGHTIN LIGHTS UP..............................................................................................................................................641 b) PART OF PANEL LIGHTING DOES NOT LIGHT UP................................................................................................................................641 M-13 SERVICE METER DOES NOT MOVE WHEN ENGINE IS STARTED;OR SERVICE METER MOVES WHEN ENGINE IS STOPPED.(FOR MACHINES WITH SPEEDOMETER)..........................................642 a) SERVICE METER DOES NOT MOVE WHEN ENGINE IS STARTED......................................................................................................................642 b) SERVICE METER MOVES WHEN ENGINE IS STOPPED..............................................................................................................................642 M-14 ENGINE WATER TEMPERATURE GAUGE SHOWS ABNORMALLY LOW TEMPERATURE...........................................................................................................644 M-15 ENGINE WATER TEMPERATURE GAUGE SHOWS NO DISPLAY...........................................................................................................................644 M-16 FUEL GAUGE ALWAYS SHOWS FULL..............................................................................................................................................645 M-17 NO DISPLAY IS GIVEN FOR FUEL LEVEL GAUGE..................................................................................................................................645 M-18 HIGH BEAM DOES NOT LIGHT UP...............................................................................................................................................647 M-19 HIGH BEAM STAYS LIGHTED UP................................................................................................................................................647 M-20 TURN SIGNAL INDICATOR DOES NOT LIGHT UP...................................................................................................................................648 M-21 TURN SIGNAL INDICATOR STAYS LIGHTED UP....................................................................................................................................648 M-22 SPEED DISPLAY STAYS AT "0" AND DOES NOT MOVE..............................................................................................................................650
KOMATSU GD510, GD520 SERIES SHOP MANUAL SEBMG5250107 – PDF DOWNLOAD:
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