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KOMATSU HD325-6 HD405-6 HD465-5 HD605-5 HD785-5 TRANSMISSION CONTROL SYSTEM (FAIL TO RANGE) SERVICE REPAIR MANUAL (SEBMW00401) – PDF DOWNLOAD
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- KOMATSU HD325-6 HD405-6 HD465-5 HD605-5 HD785-5 TRANSMISSION CONTROL SYSTEM (FAIL TO RANGE) SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:SEBMW00401
- SERIAL NUMBER:
HD325-6 5680 and up
HD405-6 1055 and up
HD465-5 4626 and up
HD605-5 1013 and up
HD785-5 4001 and up
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KOMATSU HD325-6 HD405-6 HD465-5 HD605-5 HD785-5 TRANSMISSION CONTROL SYSTEM (FAIL TO RANGE) SERVICE REPAIR MANUAL (SEBMW00401)
KOMATSU HD325-6 HD405-6 HD465-5 HD605-5 HD785-5 TRANSMISSION CONTROL SYSTEM (FAIL TO RANGE) SERVICE REPAIR MANUAL (SEBMW00401) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU HD325-6 HD405-6 HD465-5 HD605-5 HD785-5 TRANSMISSION CONTROL SYSTEM (FAIL TO RANGE) SERVICE REPAIR MANUAL (SEBMW00401)
- The automatic shift control system receives the shift lever position signal, accelerator pedal ac~ coloration signal, transmission speed signal, and signals from other switches and sensors are received, and the shift controller acts to automatically control the shift of the transmission to the optimum speed range.
- The shift controller also drives and controls the torque converter lockup solenold and overrun prevention solenoid valve in addltlon to the shift control. Each clutch in the transmission [5 equipped with an electronically controlled modulation valve, and each clutch is ind opendonrly controlled. In thls way, the initlal pressure for each clutch, build-up ratio, and torque-offtime are controlled to match the condition of the machlne (the hydraulic wave pattern for each clutch, each acceleration angle, each shift up, and each shift down are changed).
- As a result, it contributes to the reduction of shock when shitting gears, preven- tion of shift hunting, and improvement in tho du- rability of the clutches. . The transmisslon controller also receives the sig- nals from the switches and sensors in order to drive the displays, cautions, and pilot lamps on the machine monitor panel, and sends these data to the network.
TABLE OF CONTENTS:
KOMATSU HD325-6 HD405-6 HD465-5 HD605-5 HD785-5 TRANSMISSION CONTROL SYSTEM (FAIL TO RANGE) SERVICE REPAIR MANUAL (SEBMW00401)
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
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