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KOMATSU HD325-6 HD405-6 HD-465-5 HD605-5 HD-785-5 DUMP TRUCK SHOP MANUAL SEBMW00401 – PDF DOWNLOAD
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KOMATSU HD325-6 HD405-6 HD-465-5 HD605-5 HD-785-5 DUMP TRUCK SHOP MANUAL SEBMW00401 – PDF DOWNLOAD
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KOMATSU HD325-6 HD405-6 HD-465-5 HD605-5 HD-785-5 DUMP TRUCK SHOP MANUAL SEBMW00401 – PDF DOWNLOAD
Language : English
Pages : 294
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU HD325-6 HD405-6 HD-465-5 HD605-5 HD-785-5 DUMP TRUCK SHOP MANUAL SEBMW00401 – PDF DOWNLOAD
COVER................................................................................................................................................................................................................................... 1 CONTENTS................................................................................................................................................................................................................................ 2 10 STRUCTURE AND FUNCTION............................................................................................................................................................................................................... 3 AUTOMATIC SHIFT CONTROL SYSTEM...................................................................................................................................................................................................... 4 SYSTEM DIAGRAM.................................................................................................................................................................................................................. 4 ELECTRICAL CIRCUIT DIAGRAM ..................................................................................................................................................................................................... 6 TRANSMISSION CONTROLLER......................................................................................................................................................................................................... 7 CONNECTOR SIGNALS............................................................................................................................................................................................................... 8 SELF-DIAGNOSTIC FUNCTION........................................................................................................................................................................................................ 8 SHIFT LEVER POSITION AND AUTOMATIC GEAR SHIFTING RANGES......................................................................................................................................................................... 9 AUTOMATIC GEAR SHIFTING LINE GRAPH.............................................................................................................................................................................................. 10 SHIFT LEVER SWITCH.............................................................................................................................................................................................................. 12 SENSORS,SWITCHES............................................................................................................................................................................................................ 13 ENGINE SPEED SENSOR......................................................................................................................................................................................................... 13 TRANSMISSION SPEED SENSOR................................................................................................................................................................................................... 13 TRANSMISSION OIL TEMPERATURE SENSOR......................................................................................................................................................................................... 13 FILL SWITCH................................................................................................................................................................................................................. 14 ACCELERATOR SENSOR.......................................................................................................................................................................................................... 15 SHIFT LIMIT SWITCH.......................................................................................................................................................................................................... 16 MODE SELECTOR SWITCH........................................................................................................................................................................................................ 16 20 TESTING AND ADJUSTING................................................................................................................................................................................................................ 17 TESTING AND ADJUSTING PARKING BRAKE PARFORMANCE..................................................................................................................................................................................... 18 METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM.............................................................................................................................................................. 19 TROUBLESHOOTING..................................................................................................................................................................................................................... 25 SELF-DIAGNOSTIC DISPLAY METHOD FOR MONITOR PANEL AND CONTROLLERS................................................................................................................................................................ 26 TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (ELECTRONIC GOVERNOR SPECIFICATION G MODE) HD465-5:4626 AND UP,HD605-5:1013 AND UP.................................................................................................. 33 ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE.............................................................................................................................................................. 34 JUDGMENT TABLE FOR TRANSMISSION CONTROLLER,TRANSMISSION RELATED PARTS....................................................................................................................................................... 42 G-1 [0.0] (OFF) OR C010 [E. <-->1.0] ABNORMALITY IN POWER SOURCE............................................................................................................................................................ 45 G-2 C011 [E. <-->1.1] ABNORMALITY IN CONTROLLER............................................................................................................................................................................. 45 G-3 C012 [E. <-->1.2] ABNORMALITY IN RACK SENSOR SYSTEM..................................................................................................................................................................... 46 G-4 C014 [E. <-->1.4] ABNORMALITY IN GOVERNOR SOLENOID SYSTEM............................................................................................................................................................... 47 G-5 C016 [E. <-->1.6] ABNORMALITY IN GOVERNOR CUT RELAY SYSTEM.............................................................................................................................................................. 48 G-6 C018 [E. <-->1.8] ABNORMALITY IN RACK SENSOR POWER SOURCE SYSTEM........................................................................................................................................................ 49 G-7 C019 [E. <-->1.9] ABNORMALITY IN GOVERNOR SERVO SYSTEM BANK............................................................................................................................................................. 50 G-8 C01b [E. <-->1.b] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM A........................................................................................................................................................... 51 G-9 C01C [E. <-->1.C] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM B........................................................................................................................................................... 52 G-10 C01d [E. <-->1.d] ABNORMALITY IN PRE-STROKE SOLENOID SYSTEM............................................................................................................................................................ 53 G-11 C021 [E. <-->2.1] MISTAKEN CONNECTION OF CONNECTOR..................................................................................................................................................................... 54 G-12 C022 [E. <-->2.2] ENGINE OVERRUN....................................................................................................................................................................................... 55 G-13 C023 [E. <-->2.3] ENGINE OVERHEATING................................................................................................................................................................................... 55 G-14 C024 [E. <-->2.4] DROP IN ENGING OIL PRESSURE.......................................................................................................................................................................... 55 G-15 C031 [E. <-->3.1] ABNORMALITY IN ACCELERATION SENSOR SYSTEM............................................................................................................................................................ 56 G-16 C034 [E. <-->3.4] ABNORMALITY IN ENGINE WATER TEMPERATURE SYSTEM....................................................................................................................................................... 59 G-17 C036 [E. <-->3.6] ABNORMALITY IN ENGINE OIL PRESSURE SENSOR............................................................................................................................................................ 60 G-18 C055 [E. <-->5.5] ABNORMALITY IN NETWORK............................................................................................................................................................................... 61 G-19 C056 [E. <-->5.6] ABNORMALITY IN SOLENOID POWER SOURCE SYSTEM RIGHT.................................................................................................................................................... 62 G-20 C058 [E. <-->5.8] ABNORMALITY IN BACKUP POWER SOURCE SYSTEM............................................................................................................................................................ 63 G-21 C059 [E. <-->5.9] ABNORMALITY IN BACKUP POWER SOURCE SYSTEM............................................................................................................................................................ 64 G-22 C0C2 [E. <-->C.2] DEFECTIVE MODEL SELECTION DATA....................................................................................................................................................................... 65 G-23 C0C5 [E. <-->C.5] ABNORMALITY IN IDLING VALIDATION..................................................................................................................................................................... 66 G-24 ENGINE DOES NOT START.................................................................................................................................................................................................. 68 G-25 DEFECTIVE ACTUATION OF APS............................................................................................................................................................................................. 71 TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM(G MODE) HD325-6:SERIAL NO.6001 AND UP,HD405-6:SERIAL NO.2001 AND UP................................................................................................................. 79 ERROR CODE DISPLAYS AND POINTS TO REMEMBER WHEN TROUBLESHOOTING............................................................................................................................................................. 81 ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED............................................................................................................................................ 84 ENGINE CONTROLLER RELATED JUDGEMENT TABLE................................................................................................................................................................................... 92 ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE CONTROLLER SYSTEM..................................................................................................................................................................... 94 G-1 ERROR CODE [C01b][ABNORMALITY IN NE REVOLUTION SENSOR SYSTEM]........................................................................................................................................................... 98 G-2 ERROR CODE [C01C][ABNORMALITY IN G REVOLUTION SENSOR SYSTEM]............................................................................................................................................................ 99 G-3 ERROR CODE [C020][ABNORMALITY IN MODEL SELECTION SYSTEM]................................................................................................................................................................100 G-4 ERROR CODE [C022][OVERRUN]..............................................................................................................................................................................................101 G-5 ERROR CODE [C023][OVERHEAT].............................................................................................................................................................................................101 G-6 ERROR CODE [C024][DROP IN OIL PRESSURE].................................................................................................................................................................................102 G-7 ERROR CODE [C030][ABNORMALITY IN IDLING VALIDATION SIGNAL SYSTEM].......................................................................................................................................................103 G-8 ERROR CODE [C031][ABNORMALITY IN ACCELERATOR SENSOR SYSTEM].............................................................................................................................................................105 G-9 ERROR CODE [C034][ABNORMALITY IN HIGH WATER TEMPERATURE SENSOR SYSTEM]..................................................................................................................................................107 G-10 ERROR CODE [C036][ABNORMALITY IN OIL PRESSURE SWITCH SYSTEM]...........................................................................................................................................................108 G-11 ERROR CODE [C03C][ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM].........................................................................................................................................................110 G-12 ERROR CODE [C03d][ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM].......................................................................................................................................................111 G-13 ERROR CODE [C050][ABNORMALITY IN PREHEATING RELAY CONNECTING POINT SYSTEM].............................................................................................................................................112 G-14 ERROR CODE [C051][ABNORMALITY IN PREHEATING RELAY COIL SYSTEM].........................................................................................................................................................113 G-15 ERROR CODE [C054][SHORT CIRCUIT IN STARTING SWITCH C SYSTEM]...........................................................................................................................................................114 G-16 ERROR CODE [C055][ABNORMALITY IN NETWORK]..............................................................................................................................................................................115 G-17 ERROR CODE [C056][POWER SOURCE SYSTEM ABNORMALITY 1]...................................................................................................................................................................116 G-18 ERROR CODE [C057][POWER SOURCE SYSTEM ABNORMALITY 2]...................................................................................................................................................................118 G-19 ERROR CODE [C05A][ABNORMALITY IN FUEL INJECTION QUANTITY CONTROL SWITCH SIGNAL]........................................................................................................................................120 G-20 ERROR CODE [C06A][ABNORMALITY IN HIGH ENGINE WATER TEMPERATURE SENSOR SYSTEM]..........................................................................................................................................121 G-21 ERROR CODE [C070][EXCESS CURRENT IN FUEL SUPPLY PUMP PCV1 SYSTEM]......................................................................................................................................................122 G-22 ERROR CODE [C071][EXCESS CURRENT IN FUEL SUPPLY PUMP PCV2 SYSTEM]......................................................................................................................................................123 G-23 ERROR CODE [C074][DISCONNECTION IN FUEL SUPPLY PUMP PCV1 SYSTEM].......................................................................................................................................................124 G-24 ERROR CODE [C075][DISCONNECTION IN FUEL SUPPLY PUMP PCV2 SYSTEM].......................................................................................................................................................125 G-25 ERROR CODE [C077][ABNORMALITY IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM]..............................................................................................................................................126 G-26 ERROR CODE [C079][COMMON RAIL HIGH FUEL PRESSURE ABNORMALITY 1],ERROR CODE [C07A][COMMON RAIL HIGH FUEL PRESSURE ABNORMALITY 2]........................................................................................127 G-27 ERROR CODE [C07b][FUEL SUPPLY PUMP NON-FORCE FEED 1],ERROR CODE [C07C][FUEL SUPPLY PUMP NON-FORCE FEED 2]..............................................................................................................128 G-28 ERROR CODE [C07d][ABNORMALITY IN COMMON RAIL FUEL PRESSURE]............................................................................................................................................................130 G-29 ERROR CODE [C080][DEFECTIVE CONTROLLER]................................................................................................................................................................................130 G-30 ERROR CODE [C081][DISCONNECTION IN NO.1 FUEL INJECTOR <A> SYSTEM] .....................................................................................................................................................131 G-31 ERROR CODE [C082][DISCONNECTION IN NO.2 FUEL INJECTOR <E> SYSTEM]......................................................................................................................................................132 G-32 ERROR CODE [C083][DISCONNECTION IN NO.3 FUEL INJECTOR <C> SYSTEM]......................................................................................................................................................133 G-33 ERROR CODE [C084][DISCONNECTION IN NO.4 FUEL INJECTOR <F> SYSTEM]......................................................................................................................................................134 G-34 ERROR CODE [C085][DISCONNECTION IN NO.5 FUEL INJECTOR <B> SYSTEM]......................................................................................................................................................135 G-35 ERROR CODE [C086][DISCONNECTION IN NO.6 FUEL INJECTOR <D> SYSTEM]......................................................................................................................................................136 G-36 ERROR CODE [C08A][SHORT CIRCUIT IN NO.1<A>,NO.2<E>,NO.3<C> FUEL INJECTOR SYSTEM].......................................................................................................................................137 G-37 ERROR CODE [C08b][SHORT CIRCUIT IN NO.4<F>,NO.5<B>,NO.6<D> FUEL INJECTOR SYSTEM].......................................................................................................................................140 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM(A MODE) HD325-6:SERIAL NO.5680-6000,HD405-6:SERIAL NO.1055-2000,HD465-5:SEIRAL NO.4625 AND UP,HD605-5:SEIRAL NO.1013 AND UP,HD785-5:SEIRAL NO.4001 AND UP.....................143 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM......................................................................................................................................146 ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE..............................................................................................................................................................148 JUDGMENT TABLE FOR TRANSMISSION CONTROLLER,TRANSMISSION RELATED PARTS.......................................................................................................................................................168 ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM...............................................................................................................................................................170 A-1 ABNORMALITY IN POWER SOURCE.............................................................................................................................................................................................171 a) [v.v][OFF]CONTROLLER SELF-DIAGNOSTIC DISPLAY LED DOES NOT LIGHT UP...................................................................................................................................................171 b) bOO1 [E. <-->0.1,E.C<-->0.1] DROP IN VOLTAGE OF CONTROLLER POWER SOURCE IS DISPLAYED.................................................................................................................................172 c) bOdA [E. <-->d.A,E.C<-->d.A] DROP IN VOLTAGE OF BATTERY DIRECT POWER SOURCE IS DISPLAYED.............................................................................................................................173 d) bOdb [E. <-->d.b,E.C<-->d.b] DROP IN VOLTAGE OF MAIN POWER SOURCE IS DISPLAYED.......................................................................................................................................174 e) bOO2 [E. <-->0.2,E.C<-->0.2] ABNORMALITAY IN TRANSMISSION CUT RELAY POWER SOURCE IS DISPLAYED........................................................................................................................175 A-2 bOO3 [E. <-->0.3,E.C<-->0.3] ABNORMALITY IN NEUTRAL SAFETY SYSTEM IS DISPLAYED..........................................................................................................................................176 A-3 bOO5 [E. <-->0.5,E.C<-->0.5] DOUBLE ENGAGEMENT FOR CLUTCH IS DISPLAYED..................................................................................................................................................177 A-5 bOO8 [E. <-->0.8,E.C<-->0.8] ABNORMALITY IN REAR BRAKE SOLENOID SYSTEM IS DISPLAYED.....................................................................................................................................178 A-6 bOO9 [E. <-->0.9,E.C<-->0.9] ABNORMALITY IN EXHAUST BRAKE SOLENOID SYSTEM IS DISPLAYED..................................................................................................................................179 A-7.........................................................................................................................................................................................................................180 a) bOC4 [E. <-->C.4,E.C<-->C.4] SHORT CIRCUIT WITH GROUND IN BCV REAR SOLENOID IS DISPLAYED.............................................................................................................................180 b) bOC6 [E. <-->C.6,E.C<-->C.6] SHORT CIRCUIT IN BCV REAR SOLENOID IS DISPLAYED.........................................................................................................................................181 c) bOC8 [E. <-->C.8,E.C<-->C.8] DISCONNECTION IN BCV REAR SOLENOID IS DISPLAYED.........................................................................................................................................182 A-8 ABNORMALITY IN SPEED SENSOR SYSTEM......................................................................................................................................................................................183 a) b010 [E. <-->1.0,E.C<-->1.0] OR b060 [E. <-->6.0,E.C<-->6.0] DISCONNECTION IN ENGINE SPEED SENSOR [B] SYSTEM IS DISPLAYED OR FAILURE IN ENGINE SPEED SENSOR IS DISPLAYED.............................................183 b) b011 [E. <-->1.1,E.C<-->1.1] OR b061 [E. <-->6.1,E.C<-->6.1] DISCONNECTION IN INPUT SHAFT SPEED SENSOR SYSTEM IS DISPLAYED OR FAILURE OF INPUT SHAFT SPEED SENSOR IS DISPLAYED.......................................184 c) b012 [E. <-->1.2,E.C<-->1.2] OR b062 [E. <-->6.2,E.C<-->6.2] DISCONNECTION IN INTERMEDIATE SHAFT SPEED SENSOR SYSTEM IS DISPLAYED OR FAILURE OF INTERMEDIATE SHAFT SPEED SENSOR IS DISPLAYED.........................185 d) b013 [E. <-->1.3,E.C<-->1.3] OR b063 [E. <-->6.3,E.C<-->6.3] DISCONNECTION IN TRAVEL SPEED SENSOR(TRANSMISSION OUTPUT SHAFT SPEED SENSOR)SYSTEM IS DISPLAYED OR FAILURE OF OUTPUT SHAFT SPEED SENSOR IS DISPLAYED....186 A-9 SPEED SENSOR SYSTEM,CLUTCH SLIPPING.....................................................................................................................................................................................187 a) b022 [E. <-->2.2,E.C<-->2.2] OR b023 [E. <-->2.3,E.C<-->2.3] INPUT SHAFT SPEED SENSOR OR H,L CLUTCH SYSTEM IS DISPLAYED..............................................................................................187 b) b024 [E. <-->2.4,E.C<-->2.4] - b028 [E. <-->2.8,E.C<-->2.8] TRAVEL SPEED SENSOR SYSTEM OR SPEED CLUTCH(1,2,3,4,R)SYSTEM IS DISPLAYED.................................................................................188 A-10 ABNORMALITY IN MODEL SELECTION SYSTEM..................................................................................................................................................................................189 a) b014 [E. <-->1.4,E.C<-->1.4] ABNORMALITY IN MODEL SELECTION(WIRING HARNESS)IS DISPLAYED..............................................................................................................................189 b) b0A1 [E. <-->A.1,E.C<-->A.1] ABNORMALITY IN MODEL SELECTION(ROTARY SWITCH)IS DISPLAYED...............................................................................................................................190 A-11 ABNORMALITY IN SHIFT LEVER SYSTEM......................................................................................................................................................................................191 a) b007 [E. <-->0.7,E.C<-->0.7] SHORT CIRCUIT IN SHIFT LEVER ASSEMBLY POWER SOURCE IS DISPLAYED.........................................................................................................................191 b) b015 [E. <-->1.5,E.C<-->1.5] SHIFT LEVER POSITION SIGNAL INPUT FOR 2 OR MORE SYSTEM IS DISPLAYED.....................................................................................................................192 c) b016 [E. <-->1.6,E.C<-->1.6] SHIFT LEVER POSITION SIGNAL IS NOT INPUT................................................................................................................................................194 A-12 b017 [E. <-->1.7,E.C<-->1.7] ABNORMALITY IN ACCELERATOR SIGNAL IS DISPLAYED............................................................................................................................................196 A-13 b019 [E. <-->1.9,E.C<-->1.9] ABNORMALITY IN TRANSMISSION OIL TEMPERATURE SENSOR IS DISPLAYED...........................................................................................................................197 A-14 ABNORMALITY IN PRESSURE CONTROL VALVE SYSTEM...........................................................................................................................................................................198 a) b032 [E. <-->3.2,E.C<-->3.2] - b038 [E. <-->3.8,E.C<-->3.8] FILL SIGNAL(CLUTCH ON)IS DISPLAYED REGARDLESS OF COMMAND.................................................................................................198 b) b042 [E. <-->4.2,E.C<-->4.2] - b048 [E. <-->4.8,E.C<-->4.8] FILL SIGNAL IS NOT INPUT AND CLUTCH SLIPPING IS DISPLAYED................................................................................................200 b-1) INSPECTING FILL SIGNAL SYSTEM..................................................................................................................................................................................200 b-2) b042 [E. <-->4.2,E.C<-->4.2] ・ b043 [E. <-->4.3,E.C<-->4.3] INSPECTING TRANSMISSION INPUT SHAFT SPEED SIGNAL SYSTEM,H,L CLUTCH SYSTEM(CHECK CLUTCH SLIP).......................................................201 b-3) b044 [E. <-->4.4,E.C<-->4.4] ・ b048 [E. <-->4.8,E.C<-->4.8] INSPECTING TRANSMISSION OUTPUT SHAFT SPEED SIGNAL SYSTEM,1-4,R CLUTCH SYSTEM(CHECK CLUTCH SLIP)....................................................201 A-15 b052 [E. <-->5.2,E.C<-->5.2] - b058 [E. <-->5.8,E.C<-->5.8] WHEN FILL SIGNAL IS NOT INPUT(FLOW DETECTOR VALVE SYSTEM)..................................................................................................202 A-16 b071 [E. <-->7.1,E.C<-->7.1] - b078 [E. <-->7.8,E.C<-->7.8] SHORT CIRCUIT IN PRESSURE CONTROL VALVE SOLENOID SYSTEM IS DISPLAYED.......................................................................................203 A-16 b091 [E. <-->9.1,E.C<-->9.1] - b098 [E. <-->9.8,E.C<-->9.8] DISCONNECTION IN PRESSURE CONTROL VALVE SOLENOID SYSTEM IS DISPLAYED.......................................................................................203 A-17 ABNORMALITY IN SENSOR SYSTEM...........................................................................................................................................................................................205 a) b0A2 [E. <-->A.2,E.C<-->A.2] ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE SENSOR SYSTEM IS DISPLAYED..............................................................................................................205 b) b0A3 [E. <-->A.3,E.C<-->A.3] ABNORMALITY IN FUEL LEVEL SENSOR SYSTEM IS DISPLAYED....................................................................................................................................206 c) b0b3 [E. <-->b.3,E.C<-->b.3] ABNORMALITY IN AIR PRESSURE SENSOR SYSTEM IS DISPLAYED..................................................................................................................................207 d) b0b4 [E. <-->b.4,E.C<-->b.4] ABNORMALITY IN RETARDER BRAKE OIL TEMPERATURE SENSOR IS DISPLAYED.......................................................................................................................208 A-18 WARNING DISPLAY........................................................................................................................................................................................................209 a) b0d1 [E. <-->d.1,E.C<-->d.1] TRANSMISSION FILTER CLOGGED WARNING IS DISPLAYED........................................................................................................................................209 b) b0d5 [E. <-->d.5,E.C<-->d.5] TILT WARNING IS DISPLAYED...............................................................................................................................................................210 c) b0d6 [E. <-->d.6,E.C<-->d.6] DROP IN RADIATOR WATER LEVEL WARNING IS DISPLAYED.......................................................................................................................................211 d) b0d7 [E. <-->d.7,E.C<-->d.7] BATTERY CHARGE LEVEL WARNING IS DISPLAYED...............................................................................................................................................212 e) b0E5 [E. <-->E.5,E.C<-->E.5] STEERING OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED..................................................................................................................................213 f) b0F6 [E. <-->F.6,E.C<-->F.6] REAR BRAKE OIL PRESSURE WARNING IS DISPLAYED............................................................................................................................................214 A-19 b0C1 [E. <-->C.1,E.C<-->C.1] ABNORMALITY IN CONNECTOR CONNECTION IS DISPLAYED..........................................................................................................................................215 A-20........................................................................................................................................................................................................................216 a) b0d2 [E. <-->d.2,E.C<-->d.2] TORQUE CONVERTER OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED..........................................................................................................................216 b) b0E9 [E. <-->E.9,E.C<-->E.9] AIR PRESSURE DROP WARNING IS DISPLAYED..................................................................................................................................................216 c) b0F3 [E. <-->F.3,E.C<-->F.3] RETARDER BRAKE OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED............................................................................................................................216 d) b0d8 [E. <-->d.8,E.C<-->d.8] ENGINE OVERRUN ACTUATED IS DISPLAYED....................................................................................................................................................217 e) b0d9 [E. <-->d.9,E.C<-->d.9] ENGINE OVERSHOOT ACTUATED IS DISPLAYED..................................................................................................................................................217 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM(A MODE) HD325-6:SERIAL NO.6001 AND UP,HD405-6:SERIAL NO.2001 AND UP...........................................................................................................218 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM......................................................................................................................................221 ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE..............................................................................................................................................................223 JUDGMENT TABLE FOR TRANSMISSION CONTROLLER,TRANSMISSION RELATED PARTS.......................................................................................................................................................243 ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM...............................................................................................................................................................245 A-1 ABNORMALITY IN POWER SOURCE.............................................................................................................................................................................................246 a) [v.v][OFF]CONTROLLER SELF-DIAGNOSTIC DISPLAY LED DOES NOT LIGHT UP...................................................................................................................................................246 b) bOO1 [E. <-->0.1,E.C<-->0.1] DROP IN VOLTAGE OF CONTROLLER POWER SOURCE IS DISPLAYED.................................................................................................................................247 c) bOdA [E. <-->d.A,E.C<-->d.A] DROP IN VOLTAGE OF BATTERY DIRECT POWER SOURCE IS DISPLAYED.............................................................................................................................248 d) bOdb [E. <-->d.b,E.C<-->d.b] DROP IN VOLTAGE OF MAIN POWER SOURCE IS DISPLAYED.......................................................................................................................................249 e) bOO2 [E. <-->0.2,E.C<-->0.2] ABNORMALITAY IN TRANSMISSION CUT RELAY POWER SOURCE IS DISPLAYED........................................................................................................................250 A-2 bOO3 [E. <-->0.3,E.C<-->0.3] ABNORMALITY IN NEUTRAL SAFETY SYSTEM IS DISPLAYED..........................................................................................................................................251 A-3 bOO5 [E. <-->0.5,E.C<-->0.5] DOUBLE ENGAGEMENT FOR CLUTCH IS DISPLAYED..................................................................................................................................................252 A-5 bOO8 [E. <-->0.8,E.C<-->0.8] ABNORMALITY IN REAR BRAKE SOLENOID SYSTEM IS DISPLAYED.....................................................................................................................................253 A-6 bOO9 [E. <-->0.9,E.C<-->0.9] ABNORMALITY IN EXHAUST BRAKE SOLENOID SYSTEM IS DISPLAYED..................................................................................................................................254 A-8 ABNORMALITY IN SPEED SENSOR SYSTEM......................................................................................................................................................................................255 a) b010 [E. <-->1.0,E.C<-->1.0] OR b060 [E. <-->6.0,E.C<-->6.0] DISCONNECTION IN ENGINE SPEED SENSOR [B] SYSTEM IS DISPLAYED OR FAILURE IN ENGINE SPEED SENSOR IS DISPLAYED.............................................255 b) b011 [E. <-->1.1,E.C<-->1.1] OR b061 [E. <-->6.1,E.C<-->6.1] DISCONNECTION IN INPUT SHAFT SPEED SENSOR SYSTEM IS DISPLAYED OR FAILURE OF INPUT SHAFT SPEED SENSOR IS DISPLAYED.......................................256 c) b012 [E. <-->1.2,E.C<-->1.2] OR b062 [E. <-->6.2,E.C<-->6.2] DISCONNECTION IN INTERMEDIATE SHAFT SPEED SENSOR SYSTEM IS DISPLAYED OR FAILURE OF INTERMEDIATE SHAFT SPEED SENSOR IS DISPLAYED.........................257 d) b013 [E. <-->1.3,E.C<-->1.3] OR b063 [E. <-->6.3,E.C<-->6.3] DISCONNECTION IN TRAVEL SPEED SENSOR(TRANSMISSION OUTPUT SHAFT SPEED SENSOR)SYSTEM IS DISPLAYED OR FAILURE OF OUTPUT SHAFT SPEED SENSOR IS DISPLAYED....258 A-9 SPEED SENSOR SYSTEM,CLUTCH SLIPPING.....................................................................................................................................................................................259 a) b022 [E. <-->2.2,E.C<-->2.2] OR b023 [E. <-->2.3,E.C<-->2.3] INPUT SHAFT SPEED SENSOR OR H,L CLUTCH SYSTEM IS DISPLAYED..............................................................................................259 b) b024 [E. <-->2.4,E.C<-->2.4] - b028 [E. <-->2.8,E.C<-->2.8] TRAVEL SPEED SENSOR SYSTEM OR SPEED CLUTCH(1,2,3,4,R)SYSTEM IS DISPLAYED.................................................................................260 A-10 ABNORMALITY IN MODEL SELECTION SYSTEM..................................................................................................................................................................................261 a) b014 [E. <-->1.4,E.C<-->1.4] ABNORMALITY IN MODEL SELECTION(WIRING HARNESS)IS DISPLAYED..............................................................................................................................261 b) b0A1 [E. <-->A.1,E.C<-->A.1] ABNORMALITY IN MODEL SELECTION(ROTARY SWITCH)IS DISPLAYED...............................................................................................................................262 A-11 ABNORMALITY IN SHIFT LEVER SYSTEM......................................................................................................................................................................................263 a) b007 [E. <-->0.7,E.C<-->0.7] SHORT CIRCUIT IN SHIFT LEVER ASSEMBLY POWER SOURCE IS DISPLAYED.........................................................................................................................263 b) b015 [E. <-->1.5,E.C<-->1.5] SHIFT LEVER POSITION SIGNAL INPUT FOR 2 OR MORE SYSTEM IS DISPLAYED.....................................................................................................................264 c) b016 [E. <-->1.6,E.C<-->1.6] SHIFT LEVER POSITION SIGNAL IS NOT INPUT................................................................................................................................................266 A-12 b017 [E. <-->1.7,E.C<-->1.7] ABNORMALITY IN ACCELERATOR SIGNAL IS DISPLAYED............................................................................................................................................268 A-13 b019 [E. <-->1.9,E.C<-->1.9] ABNORMALITY IN TRANSMISSION OIL TEMPERATURE SENSOR IS DISPLAYED...........................................................................................................................269 A-14 ABNORMALITY IN PRESSURE CONTROL VALVE SYSTEM...........................................................................................................................................................................270 a) b032 [E. <-->3.2,E.C<-->3.2] - b038 [E. <-->3.8,E.C<-->3.8] FILL SIGNAL(CLUTCH ON)IS DISPLAYED REGARDLESS OF COMMAND.................................................................................................270 b) b042 [E. <-->4.2,E.C<-->4.2] - b048 [E. <-->4.8,E.C<-->4.8] FILL SIGNAL IS NOT INPUT AND CLUTCH SLIPPING IS DISPLAYED................................................................................................272 b-1) INSPECTING FILL SIGNAL SYSTEM..................................................................................................................................................................................272 b-2) b042 [E. <-->4.2,E.C<-->4.2] ・ b043 [E. <-->4.3,E.C<-->4.3] INSPECTING TRANSMISSION INPUT SHAFT SPEED SIGNAL SYSTEM,H,L CLUTCH SYSTEM(CHECK CLUTCH SLIP).......................................................273 b-3) b044 [E. <-->4.4,E.C<-->4.4] ・ b048 [E. <-->4.8,E.C<-->4.8] INSPECTING TRANSMISSION OUTPUT SHAFT SPEED SIGNAL SYSTEM,1-4,R CLUTCH SYSTEM(CHECK CLUTCH SLIP)....................................................273 A-15 b052 [E. <-->5.2,E.C<-->5.2] - b058 [E. <-->5.8,E.C<-->5.8] WHEN FILL SIGNAL IS NOT INPUT(FLOW DETECTOR VALVE SYSTEM)..................................................................................................274 A-16 b071 [E. <-->7.1,E.C<-->7.1] - b078 [E. <-->7.8,E.C<-->7.8] SHORT CIRCUIT IN PRESSURE CONTROL VALVE SOLENOID SYSTEM IS DISPLAYED.......................................................................................275 A-16 b091 [E. <-->9.1,E.C<-->9.1] - b098 [E. <-->9.8,E.C<-->9.8] DISCONNECTION IN PRESSURE CONTROL VALVE SOLENOID SYSTEM IS DISPLAYED.......................................................................................275 A-17 ABNORMALITY IN SENSOR SYSTEM...........................................................................................................................................................................................277 a) b0A2 [E. <-->A.2,E.C<-->A.2] ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE SENSOR SYSTEM IS DISPLAYED..............................................................................................................277 b) b0A3 [E. <-->A.3,E.C<-->A.3] ABNORMALITY IN FUEL LEVEL SENSOR SYSTEM IS DISPLAYED....................................................................................................................................278 c) b0b3 [E. <-->b.3,E.C<-->b.3] ABNORMALITY IN AIR PRESSURE SENSOR SYSTEM IS DISPLAYED..................................................................................................................................279 d) b0b4 [E. <-->b.4,E.C<-->b.4] ABNORMALITY IN RETARDER BRAKE OIL TEMPERATURE SENSOR IS DISPLAYED.......................................................................................................................280 A-18 WARNING DISPLAY........................................................................................................................................................................................................281 a) b0d1 [E. <-->d.1,E.C<-->d.1] TRANSMISSION FILTER CLOGGED WARNING IS DISPLAYED........................................................................................................................................281 b) b0d5 [E. <-->d.5,E.C<-->d.5] TILT WARNING IS DISPLAYED...............................................................................................................................................................282 c) b0d6 [E. <-->d.6,E.C<-->d.6] DROP IN RADIATOR WATER LEVEL WARNING IS DISPLAYED.......................................................................................................................................283 d) b0d7 [E. <-->d.7,E.C<-->d.7] BATTERY CHARGE LEVEL WARNING IS DISPLAYED...............................................................................................................................................284 f) b0F6 [E. <-->F.6,E.C<-->F.6] REAR BRAKE OIL PRESSURE WARNING IS DISPLAYED............................................................................................................................................285 A-19 b0C1 [E. <-->C.1,E.C<-->C.1] ABNORMALITY IN CONNECTOR CONNECTION IS DISPLAYED..........................................................................................................................................286 A-20........................................................................................................................................................................................................................287 a) b0d2 [E. <-->d.2,E.C<-->d.2] TORQUE CONVERTER OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED..........................................................................................................................287 b) b0E9 [E. <-->E.9,E.C<-->E.9] AIR PRESSURE DROP WARNING IS DISPLAYED..................................................................................................................................................287 c) b0F3 [E. <-->F.3,E.C<-->F.3] RETARDER BRAKE OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED............................................................................................................................287 d) b0d8 [E. <-->d.8,E.C<-->d.8] ENGINE OVERRUN ACTUATED IS DISPLAYED....................................................................................................................................................288 e) b0d9 [E. <-->d.9,E.C<-->d.9] ENGINE OVERSHOOT ACTUATED IS DISPLAYED..................................................................................................................................................288 90 OTHERS...............................................................................................................................................................................................................................289 ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM(HD325-6:5680～6000,HD405-6:1055～2000)..................................................................................................................................290 ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM(HD465-5:4626 AND UP,HD605-6:1013 AND UP)..............................................................................................................................291 ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM(HD785-5:4001 AND UP)..................................................................................................................................................292 ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM(HD325-6:6001 AND UP,HD405-6:2001 AND UP)..............................................................................................................................293 ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM WITH ARSC [AUTOMATIC RETARDER SPEED CONTROLLER SYSTEM](HD325-6:6001 AND UP,HD405-6:2001 AND UP).......................................................................294
S.S 13/12/24
