Komatsu HD465-5,HD605-5 Dump Truck Shop Manual SEBM015208 PDF

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Komatsu HD465-5,HD605-5 Dump Truck Shop Manual SEBM015208  – PDF DOWNLOAD

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Komatsu HD465-5,HD605-5 Dump Truck Shop Manual SEBM015208  – PDF DOWNLOAD

Language : English
Pages : 1166
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Komatsu HD465-5,HD605-5 Dump Truck Shop Manual SEBM015208  – PDF DOWNLOAD

MACHINE MODEL           SERIAL NUMBER

• HD465-5                            4626 and up
• HD605-5                            1013 and up

COVER . 1
CONTENTS 2
01 GENERAL 28
GENERAL ASSEMBLY DRAWING 29
SPECIFICATIONS 30
WEIGHT TABLE 36
LIST OF LUBRICANT AND WATER . 37
10 STRUCTURE AND FUNCTION 38
RADIATOR, TORQUE CONVERTER, OIL COOLER, AFTER COOLER, WORK EQUIPMENT OIL COOLER . 40
BRAKE OIL COOLER 41
POWER TRAIN SKELETON . 42
OUTPUT SHFT . 43
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING 44
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM 45
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT SCHEMATICS 46
TORQUE CONVERTER 47
LOCKUP SOLENOID VALVE . 52
TRANSMISSION 53
TRANSMISSION VALVE 57
ECMV(ELECTRONIC CONTROL MODULATION VALVE 58
LUBRICATION RELIEF VALVE 63
FRONT AXLE 64
REAR AXLE . 65
DIFFERENTIAL 66
FINAL DRIVE . 67
FRONT BRAKE . 68
REAR BRAKE 69
PARKING BRAKE . 70
WHEELS 71
AXLE SUPPORT 72
STEERING SYSTEM . 73
STEERING WHEEL 74
STEERING LINKAGE 75
SUSPENSION SYSTEM . 77
SUSPENSION CYLINDER . 79
AIR PIPING 84
AIR CIRCUIT DIAGRAM . 86
AIR GOVERNOR 88
SAFETY VALVE 88
CHECK VALVE . 89
DOUBLE CHECK VALVE 89
AUTO DRAIN VALVE 90
HAND BRAKE VALVE 91
BRAKE VALVE . 92
REDUCING VALVE 93
EMERGENCY BRAKE CONTROL VALVE . 95
PARKING BRAKE CONTROL VALVE . 98
RELAY VALVE . 99
PARKING BRAKE RELAY VALVE . 102
QUICK-RELEASE VALVE . 104
PARKING BRAKE CHAMBER . 104
FRONT BRAKE CHAMBER . 105
REAR BRAKE CHAMBER 106
SLACK ADJUSTER 109
HYDRAULIIC PIPING 110
HYDRAULIC CIRCUIT DIAGRAM 112
DUMP BODY CONTROL . 113
HYDRAULIC TANK AND BRAKE COOLING OIL TANK . 114
BRAKE COOLING OIL CONTROL VALVE(BCV) 115
STEERING CONTROL VALVE 116
DEMAND VALVE 120
CROSS-OVER RELIEF VALVE . 124
HOIST VALVE . 125
STEERING CYLINDER . 127
HOIST CYLINDER 127
ELECTRICAL CIRCUIT DIAGAM . 128
STOP LAMP SWITCH 133
EXHAUST BRAKE SWITCH 133
FRONT BRAKE CUT-OFF VALVE . 134
OVERRUN PREVENTION VALVE 135
EXHAUST BRAKE VALVE . 135
HORN VALVE 136
PARKING BRAKE SWITCH 136
AIR CONDIYIONER . 137
PIPING DIAGRAM 137
ELECTRICAL CIRCUIT DIAGRAM 138
REFRIGERANT CIRCUIT DIAGRAM . 140
UNIT 141
RECEIVER DRYER 142
CONDENSER . 142
COMPRESSOR 143
ENGINE CONTROL SYSTEM 144
SYSTEM DRAWING 144
AISS 145
FUEL INJECTION PUMP ELECTRONIC GOVERNOR . 146
HYDRAULIC CIRCUIT DIAGRAM . 147
ENGINE CONTROLLER . 148
SENSORS, SWITCHES . 148
ELECTRICAL CIRCUIT DIAGRAM 149
APS . 150
EXHAUST BRAKE . 152
SYSTEM DIAGRAM 152
SYSTEM CIRCUIT DIAGRAM 153
AUTOMATIC RETARD SPEED CONTROL SYSTEM . 155
SYSTEM DRAWING 155
STRUCTURE OF SYSTEM . 156
ELECTRICAL CIRCUIT DIAGRAM 157
AIR CIRCUIT DIAGRAM . 158
AUTOMATIC RETARD SPEED CONTROL 159
AUTOMATIC RETARD SPEED CONTROLLER . 160
AUTOMATIC SHIFT CONTROL SYSYTEM . 161
SYSTEM DIAGRAM 161
ELECTRICAL CIRCUIT DIAGRAM 163
TRANSMIAAION CONTROLLER . 164
CONNECTOR SIGNALS . 165
SELF-DIAGNOSTIC FUNCTION 165
SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFTING RANGES 166
AUTOMATIC GEAR SHIFTING LINE GRAPH 167
SHIFT LEVER SWITCH 170
SENSORS, SWITCHES . 171
ENGINE SPEED SENSOR . 171
TRANSMISSION SPEED SENSOR . 171
TRANSMISSION OIL TEMPERATURE SENSOR . 171
FILL SWITCH . 172
ACCELERATOR SENSOR 173
SHIFT LIMIT SWITCH 174
MODE SELECTOR SWITCH 174
AUTOMATIC EMERGENCY STEERING SYSTEM . 175
SYSTEM DIAGRAM 175
ELECTRICAL CIRCUIT DIAGRAM 176
FLOW SWITCH . 177
RELAY TIMER . 179
AUTOMATIC SUSPENSION SYSTEM . 180
STRUCTURE OF SYSTEM . 181
SYSTEM CIRCUIT DIAGRAM 182
AUTOMATIC SUSPENSION MODE SELECTION CONTROL . 183
SUSPENSION CONTROLLER . 184
SENSORS, SWITCHES . 185
STEERING ANGLE SENSOR . 185
PRESSURE SENSOR . 185
SELF-DIAGNOSTIC FUNCTION 186
PAYLOAD METER (PRINTER TYPE) 187
STRUCTURE OF SYSTEM . 187
ELECTRICAL CIRCUIT DIAGRAM 188
PRINCIPLE OF CALCULATION 189
FEATURES OF EQUIPMENT . 191
1. PAYLOAD METER 191
2. PRESSURE SENSOR 194
3. CLINOMETER . 195
4. LAMP DRIVE RELAY . 195
SELF-DIAGNOSTIC FUNCTION 196
PAYLOAD METER Ⅱ (CARD TYPE) . 197
STRUCTURE OF SYSTEM . 197
ELECTRICAL CIRCUIT DIAGRAM 198
PRINCIPLE OF MEASUREMNT . 199
FEATURES OF EACH DEVICE . 200
1. PAYLOAD METER Ⅱ 200
LEFT FACE . 201
2. PRESSURE SENSOR 228
3. CLINOMETER . 229
4. LAMP DRIVE RELAY . 229
5. SELF-DIAGNOSTIC FUNCTION . 230
MACHINE MONITOR SYSTEM 236
SYSTEM DRAWING 236
MONITOR PANEL DIAGRAM . 238
MACHINE MONITOR NORMAL DISPLAY FUNCTIONS 239
SELF-DIAGNOSTIC FUNCTION WHEN STARTING SWITCH IS OPERATED . 246
TRAVEL SPEED COMPENSATION ROTARY SWITCH . 246
SENSORS,SWITCHES 247
ENGINE OIL PRESSURE . 247
FUEL LEVEL SENSOR . 248
ENGINE WATER TEMPERATURE SENSOR . 249
RETARDER OIL TEMOERATURE SENSOR . 249
TORQUE CONVERTER OIL TEMPERATURE SENSOR . 249
AIR PRESSURE SENSOR . 249
RADIATOR WATER LEVEL SENSOR . 250
TRANSMISSION OIL FILTER SENSOR 250
STEERING OIL TEMPERATURE SENSOR 251
BRAKE STROKE SENSOR . 251
BODY SEATED SWITCH . 252
TILT SWITCH . 253
20 TESTING AND ADJUSTING 254
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS . 255
STANDARD VALUE TABLE FOR CHASSIS 256
STANDARD VALUE TABLE FOR ELECTRICAL PARTS . 261
TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 272
ADJUSTING VALVE CLEARANCE . 274
MEASURING COMPRESSION PRESSURE 275
MEASURING BLOW-BY . 276
ADJUSTING FUEL INJECTION TIMING . 277
BLEEDING AIR FROM FUEL-INJECTION PUMP . 279
ADJUSTING ENGINE STOP MOTOR CABLE . 280
ADJUSTING ACCELERATOR PEDAL . 281
ADJUSTING ENGINE,TRANSIMSSION SPEED SENSORS . 282
TESTING HYDRAULIC PRESSURE OF TORQUE CONVERTER VALVE 283
TESTING ECMV HYDRAULIC PRESSURE . 284
TESTING TORQUE CONVERTER STALL SPEED 287
TESTING BRAKE PRESSURE 289
BLEEDING AIR FROM BRAKE CIRCUIT . 290
TESTING AND ADJUSTING PARKING BRAKE PERFORMANCE . 291
TESTING WEAR OF FRONT BRAKE PAD . 292
TESTING WEAR OF REAR BRAKE DISC . 293
TESTING AND ADJUSTING SUSPENSION CYLINDER . 294
TESTING AND ADJUSTING AIR PRESSURE IN AIR CIRCUIT . 300
ADJUSTING HOIST LEVER LINKAGE . 301
ADJUSTING BODY POSITIONER . 302
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING, HOIST CIRCUIT . 303
AIR BLEEDING FROM STEERING CYLINDER . 305
ADJUSTING ELECTRONIC MONITOR . 306
ADUSTING Q [FUEL INJECTION AMOUNT] WHEN REPLACING ENGINE CONTROLLER . 307
SETTING ROTARY SWITCH WHEN REPLACING TRANSMISSION CONTROLLER 308
METHOD OF DELETING DATA FROM ENGINE CONTROLLER, TRANSMISSION CONTROLLER MEMORY(CONTROL FROM MONITOR PANEL) 309
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM 312
PROCEDURE FOR OPERATING MODULATION CHECKER 318
PERFORMONG PM CLINIC USING MANUAL SNAPSHOT(=QUICK PM) . 323
PM-CLINIC SERVICE . 327
TROUBLESHOOTING . 329
POINTS TO REMEMBER WHEN TROUBLESHOOTNG 330
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 331
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 332
CHECKS BEFORE TROUBLESHOOTING . 340
TYPE OF CONNECTOR AND POSITION OF INSTALLATION 342
CONNECTOR PIN ALLOCATION CHART 347
CONNECTION TABLE FOR CONNECTOR PIN NUKBERS 352
EXPLANATIONS OF FUNCTIONS (CONTROL MECHANISM) OF ELECTRICAL SYSTEM 362
MONITOR PANEL USER COSDES AND SERVICE MODE FUNCTION . 367
SELF-DIAGNOSTIC DISPLAY METHOD FOR MONITOR PANEL AND CONTROLLERS 383
TABLE OF SERVICE CODES AND USER CODES . 390
METHOD OF USING JUDGMENT TABLE 400
METHOD OF USING TROUBLESHOOTING CHARTS 401
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (ELECTRONIC GOVERNOR SPECIFICATION G MODE) 403
ACTION TAKEN BY SELF-DIAGNOSTIC AND PROB-LEMS ON MACHINE 404
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER, TRANSMISSION RELATED PARTS . 412
G-1 [0.0] (OFF) OR C010 [E.<–>1.0] ABNORMALITY IN POWER SOURCE . 416
G-2 C011 [E.<–>1.1] ABNORMALITY IN CONTROLLER 416
G-3 C012 [E.<–>1.2] ABNORMALITY IN RACK SENSOR SYSTEM 417
G-4 C014 [E.<–>1.4] ABNORMALITY IN GOVERNOR SOLENOID SYSTEM 418
G-5 C016 [E.<–>1.6] ABNORMALITY IN GOVERNOR CUT RELAY SYSTEM . 419
G-6 C018 [E.<–>1.8] ABNORMALITY IN RACK SENSOR POWER SOURCE SYSTEM . 420
G-7 C019 [E.<–>1.9] ABNORMALITY IN GOVERNOR SERVO SYSTEM BANK . 421
G-8 C01b [E.<–>1.6] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM A 422
G-9 C01c [E.<–>1.C] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM B 423
G-10 C01d [E.<–>1.d] ABNORMALITY IN PRE-STROKE SOLENOID SYSTEM . 424
G-11 C021 [E.<–>2.1] MISTAKEN CONNECTION OF CONNECTOR 425
G-12 C022 [E.<–>2.2] ENGINE OVERRUN 426
G-13 C023 [E.<–>2.3] ENGINE OVERHEATING 426
G-14 C024 [E.<–>2.4] DROP IN ENGINE OIL PRESSURE . 426
G-15 C031 [E.<–>3.1] ABNORMALITY IN ACCELERATON SENSOR SYSTEM . 427
G-16 C034 [E.<–>3.4] ABNORMALITY IN ENGINE WATER TEMPERATURE SYETEM . 430
G-17 C036 [E.<–>3.6] ABNORMALITY IN ENGINE OIL PRESSURE SENSOR 431
G-18 C055 [E.<–>5.5] ABNORMALITY IN NETWORK 432
G-19 C056 [E.<–>5.6] ABNORMALITY IN SOLENOID POWER SOURCE SYSTEM RIGHT . 433
G-20 C058 [E.<–>5.8] ABNORMALITY IN BACKUP POWER SOURCE SYSTEM 434
G-21 C059 [E.<–>5.9] ABNORMALITY IN BACKUP SOURCE SYSTEM . 435
G-22 C0C2 [E.<–>C.2] DEFECTIVE MODEL SELECTION DATA 436
G-23 C0C4 [E.<–>C.4] ABNORAMLITY IN ACCELERATION SENSOR SYSTEM . 437
G-24 C0C5 [E.<–>C.5] ABNORAMLITY IN IDLING VALIDATION 440
G-25 ENGINE DOES NOT START 442
G-26 DEFECTIVE ACTUATION OF APS . 445
TROUBLESHOOTING OF ENGINE SYSTEM (S MODDE) 453
METHOD OF USING TROUBLESHOOTING CHART . 454
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) . 458
S-2 ENGINE DOES NOT START . 460
a) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT(FUEL IS NOT BEING INJECTED) 460
b) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START(FUEL IS BEING INJECTED) 461
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 462
S-4 ENGINE STOPS DURING OPERATIONS 463
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) . 465
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER) 466
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTON) . 467
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE 468
S-9 OIL BECOMES CONTAMINATED QUICKLY 469
S-10 FUEL CONSUMPTION IS EXCESSIVE 470
S-11 OIL IS COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN . 471
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) . 472
S-13 OIL LEVEL RISES 473
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) . 474
S-15 ABNORMAL NOISE IS MADE . 475
S-16 VIBRATION IS EXCESSIVE . 477
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A MODE) 478
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 481
ACTION TAKEN BY SELF-DIAGNOSTIC AND PROBLEMS ON MACHINE . 483
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER, TRANSMISSION RELATED PARTS . 503
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM . 505
A-1 ABNORMALITY IN POWER SOURCE SYSTEM 506
a) [u.u] [OFF] CONTROLLER SELF-DIAGNOSTIC DISPLAY LED DOES NOT LIGHT UP . 506
b) bOO1 [E. <–>0.1, E.C<–>0.1] DROP IN VOLTAGE OF CONTROLLER POWER SOURCE IS DISPLAYED 507
c) bOdA [E. <–>d.A, E.C<–>d.A] DROP IN VOLTAGE OF BATTERY DIRECT POWER SOURCE IS DISPLAYED 508
d) bOdb [E. <–>d.b, E.C<–>d.b] DROP IN VOLTAGE OF MAIL POWER SOURCE IS DISPLAYED 509
e) bOO2 [E. <–>0.2, E.C<–>0.2] ABNORMALITAY IN TRANSMISSION CUT RELAY POWER SOURCE IS DISPLAYED . 510
A-2 bOO3 [E. <–>0.3, E.C<–>0.3] ABNORMALITY IN NEUTRAL SAFETY SYSTEM IS DISPLAYED . 511
A-3 bOO5 [E. <–>0.5, E.C<–>0.5] DOUBLE ENGAGEMENT FOR CLUTCH IS DISPLAYED . 512
A-4 bOO6 [E. <–>0.6, E.C<–>0.6] ABNORMALITY IN TRANSMISSION [CUT RELAY] SYSTEM DISPLAYED 513
A-5 bOO8 [E. <–>0.8, E.C<–>0.8] ABNORMALITY IN REAR BRAKE SOLENOID SYSTEM IS DISPLAYED 514
A-6 bOO9 [E. <–>0.9,E.C<–>0.9] ABNORMALITY IN EXHAUST BRAKE SOLENOID SYSTEM IS DISPLAYED 515
A-7 516
a) bOC4 [E. <–>C.4, E.C<–>C.4] SHORT CIRCUIT WITH GROUND IN BCV REAR SOLENOID IS DISPLAYED 516
b) bOC6 [E. <–>C.6, E.C<–>C.6] SHORT CIRCUIT IN BCV REAR SOLENOID IS DISPLAYED 517
c) bOC8 [E. <–>C.8, E.C<–>C.8] DISCONNECTION IN BCV REAR SOLENOID IS DISPLAYED 518
A-8 ABNORMALITY IN SPEED SENSOR SYSTEM . 519
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 (ELECTRONIC GOVERNOR SPECIFICATION MACHINE) OR FAILURE OF ENGINE SPEED IS DISPLAYED (ELECTRONIC GOVERNOR SPECIFICATION MACHINE) 519
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 . 520
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 . 521
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 522
A-9 SPEED SENSOR SYSTEM, CLUTCH SLIPPING 523
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 523
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 . 524
A-10 ABNORMALITY IN MODEL SELECTION (WIRING HARNESS) IS DISPLAYED . 525
a) b014 [E. <–>1.4, E.C<–>1.4] ABNORMALITY IN MODEL SELECTION(WIRING HARNESS)IS DISPLAYED . 525
b) b0A1 [E. <–>A.1, E.C<–>A.1] ABNORMALITY IN MODEL SELECTION(ROTARY SWITCH)IS DISPLAYED 526
A-11 ABNORMALITY IN SHIFT LEVER SYSTEM 527
a) b007 [E. <–>0.7, E.C<–>0.7] SHORT CIRCUIT IN SHIFT LEVER ASSEMBLY POWER SOURCE IS DISPLAYED 527
b) b015 [E. <–>1.5, E.C<–>1.5] SHIFT LEVER POSITION SIGNAL INPUT FOR 2 OR MORE SYSTEM IS DISPLAYED 528
c) b016 [E. <–>1.6, E.C<–>1.6] SHIFT LEVER POSITION SIGNAL IS NOT INPUT . 530
A-12 b017 [E. <–>1.7, E.C<–>1.7] ABNORMALITY IN ACCELERATOR SIGNAL IS DISPLAYED . 532
A-13 b019 [E. <–>1.9, E.C<–>1.9] ABNORMALITY IN TRANSMISSION OIL TRMPERATURE SENSOR IS DISPLAYED 533
A-14 ABNORMALITY IN PRESSURE CONTROL VALVE SYSTEM . 534
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 534
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 536
b-1) INSPECTING FILL SIGNAL SYSTEM 536
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) 537
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(INSPECTING CLUTCH SLIP) . 537
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) 538
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 . 539
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 . 539
A-17 ABNORMALITY IN SENSOR SYSTEM . 541
a) b0A2 [E. <–>A.2, E.C<–>A.2] ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE SENSOR SYSTEM IS DISPLAYED . 541
b) b0A3 [E. <–>A.3, E.C<–>A.3] ABNORMALITY IN FUEL LEVEL SENSOR SYSTEM IS DISPLAYED . 542
c) b0b3 [E. <–>b.3, E.C<–>b.3] ABNORMALITY IN AIR PRESSURE SENSOR SYSTEM IS DISPLAYED . 543
d) b0b4 [E. <–>b.4, E.C<–>b.4] ABNORMALITY IN RETARDER BRAKE OIL TEMPERATURE SENSOR IS DISPLAYED 544
A-18 WARNING DISPLAY 545
a) b0d1 [E. <–>d.1, E.C<–>d.1] TRANSMISSION FILTER CLOGGED WARNING IS DISPLAYED . 545
b) b0d5 [E. <–>d.5, E.C<–>d.5] TILT WARNING IS DISPLAYED 546
c) b0d6 [E. <–>d.6, E.C<–>d.6] DROP IN RADIATOR WATER LEVEL WARNING IS DISPLAYED 547
d) b0d7 [E. <–>d.7, E.C<–>d.7] BATTERY CHARGE LEVEL WARNING IS DISPLAYED 548
e) b0E5 [E. <–>E.5, E.C<–>E.5] STEERING OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED . 549
f) b0F6 [E. <–>F.6, E.C<–>F.6] REAR BRAKE OIL PRESSURE WARNING IS DISPLAYED . 550
A-19 b0C1 [E. <–>C.1, E.C<–>C.1] ABNORMALITY IN CONNECTOR CONNECTION IS DISPLAYED . 551
A-20 552
a) b0d2 [E. <–>d.2, E.C<–>d.2] TORQUE CONVERTER OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED . 552
b) b0E9 [E. <–>E.9, E.C<–>E.9] AIR PRESSURE DROP WARNING IS DISPLAYED . 552
c) b0F3 [E. <–>F.3, E.C<–>F.3] RETARDER BRAKE OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED . 552
d) b0d8 [E. <–>d.8, E.C<–>d.8] ENGINE OVERRUN PREVENTION BRAKE ACTUATED (※1) OR ENGINT=E OVERRUN PREVENTION BRAKE ACTUATED 1 (※2) IS DISPLAYED 553
e) b0d9 [E. <–>d.9, E.C<–>d.9] ENGINE OVERSHOOT ACTUATED IS DISPLAYED . 553
f) b0dF [E. <–>d.F, E.C<–>d.F] ENGINE OVERRUN PREVENTION ACTUATED 2 IS DISPLAYED 554
TEOUBLESHOOTING OF SUSPENSION CONTROLLER SYSTEM (SP MODE) . 555
JUDGMENT TABLE FOR SUSPENSION CONTROLLER, SUSPENSION RELAED PARTS . 556
ACTION TAKEN BYSELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE . 558
ELECTRICAL CIRCUIT DIAGRAM OF SUSPENSION CONTROLLER SYSTEM 562
SP-1 d001 [ALL OFF or E.<–>01] ABNORMALITY IN POWER SOURCE IS DISPLAYED 564
SP-2 d011 [E.<–>11 IS DISPLAYED] ABNORMALITY IN PRESSURE SENSOR [RIGHT] SYSTEM IS DISPLAYED 565
SP-3 d012 [E.<–>12 IS DISPLAYED] ABNORMALITY IN PRESSURE SENSOR [LEFT] SYSTEM IS DISPLAYED . 566
SP-4 d015 [E.<–>15 IS DISPLAYED] ABNORMALITY IN TRAVEL SPEED SENSOR SYSTEM IS DISPLAYED 567
SP-5 d016 [E.<–>16 IS DISPLAYED] ABNORMALITY IN STEERING SENSOR SYSTEM IS DISPLAYED 568
SP-6 d0C2 [E.<–>C2 IS DISPLAYED] DEFECTIVE MODEL SELECTION DATA IS DISPLAYED . 569
SP-7 d021 [E.<–>21 IS DISPLAYED] ABNORMALITY IN SOLENOID [1] SYSTEM IS DISPLAYED . 570
SP-8 d022 [E.<–>22 IS DISPLAYED] ABNORMALITY IN SOLENOID [2] SYSTEM IS DISPLAYED . 571
SP-9 d023 [E.<–>23 IS DISPLAYED] ABNORMALITY IN SOLENOID [3] SYSTEM IS DISPLAYED . 572
SP-10 d0C1 [E.<–>C1 IS DISPLAYED] DISCONNECTION IN NETWROK IS DISPLAYED 573
SP-11 d0C3 [E.<–>C3 IS DISPLAYED] DEFECTIVE TRAVEL SPEED COMPENSATION DATA IS DISPLAYED 574
TROUBLESHOOTING OF PAYLOAD METER (PRINTER TYPE) SYSTEM (LP MODE) 575
SERVICE CODES AND SELF-DIAGNOSIS OF PAYLOAD METER (PRINTER TYPE) 576
ELECTRICAL CIRCUIT DIAGRAM FOR PAYLOAD METER (PRINTER TYPE) SYSTEM . 577
LP-1 NO DISPLAY APPEARS WHEN STARTING SWITCH IS TURNED ON . 579
LP-2 CALIBRATION DEMAND(CAL FLASHES) IS SHOWN CONTINUOUSLY AFTER STARTING SWITCH IS TUENED ON . 580
LP-3 CALIBRATION CANNOT BE CARRIED OUT 581
LP-4 AFTER STARTING SWITCH IS TURNED ON, ALL EXTERNAL DISPLAY LAMPS DO NIOT LIGHT UP 584
LP-5 CONDITION DOES NOT EXIST FOR LAMPS TO LIGHT UP, BUT EXTERNAL DISPLAY LAMPS LIGHT UP . 586
LP-6 LEVEL OF LIGHTING UP OF EXTERNAL DISPLAY LAMPS IS NOT CORRECT 587
LP-7 ABNORMALITY IN DISPLAY LOGIC . 589
LP-8 E01-E04 IS DISPLAYED . 594
LP-9 E11-E14 IS DISPLAYED . 595
LP-10 E21-E28 IS DISPLAYED BY SENSOR CHECK . 596
LP-11 E31 IS DISPLAYED 597
LP-12 E32 IS DISPLAYED 599
LP-13 E41 IS DISPLAYED 601
LP-14 E42 IS DISPLAYED 602
LP-15 PRINTER DOES NOT PRINT ANYTHING (BLANK PAPER COMES OUT) . 603
LP-16 PRINTER PRINTS ONLY “NO DATA” . 603
LP-17 PRINTER DOES NOT PRINT OUT WHEN PRT SWITCH IS PRESSED . 603
LP-18 “PAPE”FLASHES . 604
LP-19 TIME IS WRONG 604
LP-20 E33 IS DISPLAYED 604
TROUBLESHOOTING OF PAYLOAD METER Ⅱ (CARD TYPE)SYSTEM(LC NODE) . 605
SERVICE CODES AND SELF-DIAGNOSIS OF PAYLOAD METER Ⅱ (CARD TYPE) . 606
ELECTRICAL CIRCUIT DIAGRAM FOR PAYLOAD METER Ⅱ (CARD TYPE) SYSTEM . 609
LC-1 NO DISPLAY APPEARS WHEN STARTING SWITCH IS TURNED ON . 611
LC-2 AFTER STARTING SWITCH IS TURNED ON, ALL EXTERNAL DISPLAYED LAMPS DO NOT LIGHT UP 612
LC-3 CONDITION DOES NOT EXIST FOR LAMPS TO LIGHT UP, BUT EXTERNAL DISPLAY LAMPS LIGHT UP . 613
LC-4 LEVEL OF LIGHTING UP OF EXTERNAL DISPLAY LAMPS IS NOT CORRECT 614
LC-5 CYCLE DATA IS NOT RECORDED, ON/OFF DATA IS NOT RECORDED:BATTERY CHARGE SIGNAL SYSTEM: ENGINE NOT STARTED IS DETECTED . 616
LC-6 CALIBRATION CANNOT BE CARRIED OUT, TIME DISPLAY DOES NOT MATCH CONDITIONS: SHIFT LEVER N POSITION SIGNAL SYSTEM 617
LC-7 ABNORMALITY IN DISPLAY LOGIC . 618
LC-8 B-FL REMAINS DISPLAYED AND DOES NOT CHANGE: BODY FLOAT RELAY SYSTEM: WHEN NOT DUMPING AND WHEN DUMP LEVER IS NOT AT FLOAT POSITION . 620
LC-9 F-09 IS DISPLAYED: DROP IN VOLTAGE OF BACK-UP BATTERY BULIT INTO PAYLOAD METER . 621
LC-10 FULL DISPLAY APPEARS 621
LC-11 F-20 IS DISPLAYED: SENSOR POWER SOURCE VOLTAGE SYSTEM . 622
LC-12 F-21-F-24 IS DISPLAYED: DISCONNECTION, SHORT CIRCUIT WITH GROUND IN SUSPENSION PRESSURE SENSOR SYSTEM . 623
LC-13 F-25-F-28 IS DISPLAYED: SHORT CIRCUIT IN SUSPENSION PRESSURE SENSOR SYSTEM POWER SOURCE . 625
LC-14 F. CAL IS DISPLAYED: CALIBRATION NOT CARRIED OUT, DAMAGED DATA INSIDE PAYLOAD METER . 626
LC-15 F-41-F-45 IS DISPLAYED: SHORT CIRCUIT IN EXTERNAL DISPLAY LAMP SYSTEM POWER SOURCE . 627
LC-16 L-BAD IS DISPLAYED : CYCLE DATA SAVED WHEN MACHINE WAS SWAYING 629
LC-18 F-31 IS DISPLAYED: DISCONNECTION, SHORT CIRCUIT WITH GROUND IN CLINOMETER SYSTEM 631
LC-19 F-32 IS DISPLAYED: SHORT CIRCUIT WITH CLINOMETER SYSTEM POWER SOURCE 632
LC-20 F-18 IS DISPLAYED: DISCONNECTION IN BATTERY CHARGE SIGNAL . 633
TROUBLESHOOTING OF ABS/ASR SYSTEM 634
FLOWCHART OF TROUBLESHOOTING . 635
WHEN ONLY ABS IS INSTALLED 635
WHEN ABS AND ASR ARE INSTALLED 636
METHOD OF DELETING TROUBLE DATA OF ECU 637
PROCEDURE FOR DELETING TEOUBLE DATA . 637
METHOD OF TROUBLESHOOTING USING SELF-DIAGNOSTIC FUNCTION OF ECU . 638
INDEX (TROUBLESHOOTING CODE) 639
SYSTEM CHECK SHEET FOR SYSTEM CHECKER . 641
TROUBLESHOOTING . 649
W-1 WARNING LAMP DOES NOT LIGHT UP . 649
I-1 ASR INFORMATION LAMP DOES NOT GO OFF 650
ASR-1 TROUBLE IN ASR CONTROL VALVE (FOR ONLY MACHINE WITH ABS AND ASR) 651
ASR-2 . 652
ABS-1 TROUBLE IN ECU 653
ABS-2 TROUBLE IN RIGHT FRONT PRESSURE CONTROL VALVE . 654
ABS-3 TROUBLE IN LEFT FRONT PRESSURE CONTROL VALVE . 655
ABS-4 TROUBLE IN LEFT REAR PRESSURE CONTROL VALVE . 656
ABS-5 TROUBLE IN RIGHT REAR PRESSURE CONTROL VALVE 657
ABS-6 TROUBLE IN RIGHT FRONT WHEEL SPEED SENSOR . 658
ABS-10 ABNORMALITY IN RIGHT FRONT WHEEL SPEED SENSOR OUTPUT . 658
ABS-7 TROUBLE IN LEFT FRONT WHEEL SPEED SENSOR 659
ABS-11 ABNORMALITY IN LEFT FRONT WHEEL SPEED SENSOR OUTPUT 659
ABS-8 TROUBLE IN LEFT REAR WHEEL SPEED SENSOR . 660
ABS-12 ABNORMALITY IN LEFT REAR WHEEL SPEED SENSOR OUTPUT . 660
ABS-9 TROUBLE IN RIGHT REAR WHEEL SPEED SENSOR 661
ABS-13 ABNORMALITY IN RIGHT REAR WHEEL SPEED SENSOR OUTPUT 661
ABS-14 TROUBLE IN VALVE RELAY (VR2) . 662
ABS-15 TROUBLE IN VALVE RELAY (VR1) . 663
ABS-16 TROUBLE IN VALVE RELAY (VR2) . 664
ABS-17 TROUBLE IN VALVE RELAY (VR1) . 665
ABS-18 ABNORMALITY IN SOURCE VOLTAGE 666
TROUBLESHOOTING OF ARSC [AUTOMATIC RETARDER SPEED CONTROLLER] SYSTEM (R NODE) . 667
OUTLINE . 668
ELECTRCAL CIRCUIT DIAGRAM FOR ARSC (AUTOMATIC RETADER SPEED CONTROLLER) SYSTEM 671
R-1 0.1 (ABNORMALITY IN POWER SOURCE VOLTAGE) IS DISPLAYED 673
R-2 1.0 (DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED 674
R-3 1.3 (DISCONNECTION IN TRANSMISSION OUTPUT SHAFT SPEED SENSOR SYSTEM) IS DISPLAYED . 675
R-4 1.5 (FAILURE IN RETARDER OIL TEMPERATURE SENSOR SYSTEM) IS DISPLAYED 676
R-5 1.7 (FAILURE IN ACCELERATOR SIGNAL SYSTEM) IS DISPLAYED . 677
R-6 1.8 (FAILURE IN SUSPENSION PRESSURE SENSOR “LEFT” SYSTEM) IS DISPLAYED 678
R-7 1.9 (FAILURE IN SUSPENSION PRESSURE SENSOR “RIGHT” SYSTEM) IS DISPLAYED . 679
R-8 4.2 (DISCONNECTION IN EXHAUST BRAKE SELECTOR SIGNAL SYSTEM) IS DISPLAYED 680
R-9 4.3 (DISCONNECTION IN ARSC CAUTION LAMP SYSTEM) IS DISPLAYED 681
R-10 4.4 (DISCONNECTION IN READY LAMP SYSTEM) IS DISPLAYED 682
R-11 4.5 (DISCONNECTOIN IN PANEL CAUTION AND BUZZER SYSTEM) IS DISPLAYED 683
R-12 5.2 (SHORT CIRCUIT WITH GROUND IN EXHAUST BRAKE SELECTOR SIGNAL OUTPUT SYSTEM) IS DISPLAYED 684
R-13 5.3 (SHORT CIRCUIT WITH GROUND IN ARSC CAUTION LAMP SYSTEM) IS DISPLAYED . 685
R-14 5.4 (SHORT CIRCUIT WITH GROUND IN READY OUTPUT CIRCUIT SYSTEM) IS DISPLAYED 686
R-15 5.5 (SHORT CIRCUIT WITH GROUND IN PANEL CAUTION LAMP AND BUZZER OUTPUT SYSTEM) IS DISPLAYED 687
R-16 6.0 (FAILURE IN ENGINE SPEED SYSTEM) IS DISPLAYED 688
R-17 7.0 (DISCONNECTION IN TRAVEL SPEED DISPLAY UP OUTPUT SYSTEM) IS DISPLAYED 689
R-18 7.1 (DISCONNECTION IN TRAVEL SPEED DISPLAY DOWN OUTPUT SYSTEM) IS DISPLAYED 690
R-19 7.2 (DISCONNECTION IN TRAVEL SPEED DISPLAY CLEAR OUTPUT SYSTEM) IS DISPLAYED . 691
R-20 7.3 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY UP OUTPUT SYSTEM) IS DISPLAYED . 692
R-21 7.4 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY DOWN OUTPUT SYSTEM) IS DISPLAYED 693
R-22 7.5 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY CLEAR OUTPUT SYSTEM)IS DISPLAYED 694
R-23 8.1 (SHORT CIRCUIT WITH GROUND IN PRESSURE CONTROL VALVE SYSTEM) IS DISPLAYED 695
R-24 8.3 (DISCONNECTION IN PRESSURE CONTROL VALVE SYSTEM) IS DISPLAYED 696
R-25 8.5 (FAILURE IN PRESSURE CONTEOL VALVE [PRESSURE CONTROL VALVE REMAINS OPEN) IS DISPLAYED 697
R-26 8.7 (FAILURE IN PRESSURE CONTROL VALVE(PRESSURE CONTROL VALVE DOES NOT OPEN) IS DISPLAYED 698
R-27 8.9 (SHORT CIRCUIT WITH GROUND IN PRESSURE SWITCH VALVE SYSTEM) IS DISPLAYED . 699
R-28 9.0 (DISCONNECTION IN PRESSURE SWITCH VALVE SYSTEM) IS DISPLAYED . 700
R-29 9.1 (FAILURE IN PRESSURE SWITCH VALVE SYSTEM (REMAINS OPEN)) IS DISPLAYED 701
R-30 9.2 (FAILURE IN PRESSURE SWITCH VALVE SYSTEM (DOES NOT OPEN)) IS DISPLAYED . 702
R-31 9.3 (DISCONNECTION IN SYSTEM SWITCH SYSTEM) IS DISPLAYED . 703
R-32 9.4 (SHORT CIRCUIT WITH GROUND IN SYSTEM SWITCH SYSTEM) IS DISPLAYED . 704
R-33 9.5 (DISCONNECTION, SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED SETTING SWITCH SYSTEM) IS DISPLAYED 705
R-101 SET SPEED CANNOT BE SET . 706
R-102 FAILURE CODE IS ALWAYS CLEARED (CONTROLLER DISPLAY WINDOW ALWAYS SHOWS “–“) OR FAILURE CODE CANNOT BE CLEARED 709
R-103 EFFECT OF RETARDER IS TOO STRONG WHEN MACHINE IN EMPTY, OR TOO WEAK WHEN MACHINE IS LOADED (DOES NOT JUDGE LOADED/UNLOADED CONDITION PROPERLY) 710
R-105 WHEN TRAVELING DOWNHILL, EVEN WHEN SET SPEED IS EXCEEDED, NO CONTROL IS CARRLED OUT . 711
R-106 MONITOR LAMP (BUZZER) STAYS ON (OR OFF) . 712
R-107 READY LAMP DOES NOT LIGHT UP (OR STAYS LIGHTED UP) 713
R-108 EXHAUST BRAKE DOES NOT WORK PROPERLY (EXHAUST BRAKE IS ACTUATED WHEN EXHAUST BRAKE SWITCH IS OFF; OR EXHAUST BRAKE IS NOT ACTUATED WHEN EXHAUST BRAKE SWITCH IS ON) . 715
R-109 THERE IS DIFFERENCE BETWEEN TRAVEL SPEED ROD VALUE AND ACTUAL MACHINE VALUE . 717
R-110 RETARDER LAMP DOES NOT LIGHT UP, OR STAYS LIGHTED UP 719
R-111 TRAVEL SPEED DISPLAY ALWAYS GIVES DISPLAY (OR DOES NOT GIVE ANY DISPLAY) 720
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 721
H-1 MACHINE DOES NOT START 722
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE JERKS) 724
H-3 LOCK-UP CLUTCH CANNOT BE DISENGAGED (ENGINE STALLS) . 724
H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING . 725
H-5 TRANSMISSION DOES NOT SHIFT UP . 725
H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING . 726
H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR 730
H-8 TORQUE CONVERTAR OIL TEMPERATURE IS HIGH 732
H-9 TORQUE CONVERTER OIL PRESSURE IS LOW 733
H-10 FRONT BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE 734
H-11 REAR BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE . 735
H-12 STEERING WHEEL IS HEAVY 736
H-13 STEERING WHEEL DOES NOT WORK . 737
H-14 STEERING WHEEL VIBRATES 737
H-15 HOIST CYLINDER LACKS LIFTING FORCE (LIFTING SPEED) . 738
H-16 HOIST CYLINDER DOES NOT WORK . 739
H-17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY . 740
H-18 AIR PRESSURE DOES NOT RISE (LOW-PRESSURE BUZZER DOES NOT STOP, AIR GAUGE DOES NOT RISE TO GREEN RANGE) . 741
TROUBLESHOOTING OF MONITOR PANEL SYSTEM (P MODE) 742
METHOD OF SELF-DIAGNOSTIC DISPLAY FOR MONITOR PANEL AND CONTROLLERS . 744
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE 745
ELECTRICAL CIRCUIT DIAGRAM FOR MONITOR PANEL SYSTEM . 749
P-1 CHECK PATTERN FOR WIRING HARNESSES BETWEEN MODULES 751
P-2 NOTHING ON MONITOR PANAL WORKS 755
P-3 LH, RH MODULE AND FUEL GAUGE DO NOT WORK 756
P-4 LH, RH MODULE AND FUEL GAUGE DO NOT WORK 757
P-5 RH MODULE DOES NOT WORK 758
P-6 LH MODULE DOES NOT WORK . 759
P-7 TRAVEL CALCULATOR DOES NOT WORK . 760
P-8 SERVICE METER DISPLAY DOES NOT WORK CORRECTLY . 761
P-9 CENTRAL WARNING LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS FAILURE CODE (MONITOR PANEL DISPLAY) [A002] 762
P-10 CENTRAL WARNING LAMP STAYS LIGHTED UP 763
P-11 ALARM BUZZER DOES NOT WORK, OR MONITOR PANEL DETECTS FAILURE CODE [A003] . 764
P-12 ALARM BUZZER CONTINUES TO SOUND 765
P-13 ALL DATA FROM SHIFT CONTROLLER (SPEEDOMETER, TACHOMETER, SHIFT INDICATOR, ETC.) ARE ABNORMAL (NOTHING IS DISPLAYED, OR DISPLAY DOES NOT CHANGE), OR MONITOR PANEL DETECTS SERVICE CODE [A013] OR MONITOR PANEL DETECTS SERVICE CODE [A018] . 766
P-14 SUSPENSION MODE, POWER/ECONOMY MODE DISPLAY ARE ABNORMAL (NOTHING IS DISPLAYED, OR DISPLAY DOES NOT CHANGE), OR MONITOR PANEL DETECTS SERVICE CODE [A016] 767
P-15 GAUGE DISPLAYS ARE ABNORMAL (NOTHING IS DISPLAYED, OR DISPLY DOES NOT CHANGE) 768
P-16 COOLING WATER LEVEL DROP CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001] 769
P-17 COOLING WATER LEVAL DROP CAUTION LAMP STAYS LIGHTED UP . 770
P-18 EMERGENCY STEERING PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001] 771
P-19 EMERGENCY STEERING PILOT LAMP STAYS LIGHTED UP 772
P-20 ENGINE OIL PRESSURE DROP CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001] 773
P-21 ENGINE OIL PRESSURE DROP CAUTION LAMP STAYS LIGHTED UP . 774
P-22 EXHAUST BRAKE PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001] . 775
P-23 EXHAUST BRAKE PILOT LAMP STAYS LIGHTED UP 776
P-24 CHARGING CIRCUIT ABNORMALITY CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001] 777
P-25 CHARGING CIRCUIT ABNORMALITY CAUTION LAMP STAYS LIGHTED UP . 778
P-26 TRANSMISSION FILTER CLOGGING CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001] 779
P-27 TRANSMISSION FILTER CLOGGING CAUTION LAMP STAYS LIGHTED UP . 780
P-28 BRAKE STROKE CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001] 781
P-29 BRAKE STROKE CAUTION LAMP STAYS LIGHTED UP . 782
P-30 PREHEATING SWITCH PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001] . 783
P-31 PREHEATING SWITCH PILOT LAMP STAYS LIGHTED UP 784
P-32 TILT WARNING LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001] 785
P-33 TILT WARNING LAMP STAYS LIGHTED UP . 786
P-34 BODY FLOAT (EXCEPT FLOAT) PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001] . 787
P-35 BODY FLOAT (EXCEPT FLOAT) PILOT LAMP STAYS LIGHTED UP 788
P-36 REAR BRAKE PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001] 789
P-37 REAR BRAKE PILOT LAMP STAYS LIGHTED UP . 790
P-38 PARKING BRAKE PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001] . 791
P-39 PARKING BRAKE PILOT LAMP STAYS LIGHTED UP 792
P-40 MAINTENANCE CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001] . 793
P-41 MAINTENANCE CAUTION LAMP STAYS LIGHTED UP 794
P-42 STEERING OIL TEMPERATURE CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001] 795
P-43 STEERING OIL TEMPERATURE CAUTION LAMP STAYS LIGHTED UP . 796
P-44 DIFFERENTIAL LOCK PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001] . 797
P-45 DIFFERENTIAL LOCK PILOT LAMP STAYS LIGHTED UP 798
P-46 HIGH BEAM DISPLAY DOES NOT LIGHT UP 799
P-47 TURN SIGNAL LAMP (RIGHT) DOES NOT LIGHT UP . 801
P-48 TURN SIGNAL LAMP (LEFT) DOES NOT LIGHT UP 802
P-49 LAMP CHECK SWITCH DOES NOT WORK 803
P-50 AISS SWITCH DOES NOT WORK 804
P-51 EXHAUST BRAKE SWITCH DOES NOT WORK . 805
P-52 MODE CHANGE SWITCH (1) DOES NOT WORK . 806
P-53 MODE CHANGE SWITCH (2) DOES NOT WORK . 807
P-54 KPH/MPH SPEEDOMETER UNIT SELECTOR DOES NOT WORK 808
P-55 DEFECTIVE OPERATION OF ALL SWITCH INPUTS . 809
P-56 MONITOR PANEL DETECTS SERVICE CODES [A014] OR [A019] . 810
P-57 MONITOR PANEL DETECTS SERVICE CODE [A015] 811
P-58 MONITOR PANEL DETECTS SERVICE CODE [A011] 812
P-59 MONITOR PANEL DETECTS SERVICE CODE [A012] 812
P-60 MONITOR PANEL DETECTS SERVICE CODE [A000] 812
VHMS MACHINE HEALTH DIAGNOSIS SYSTEM (OPT) 813
1. BASIC PRECAUTIONS 814
1-1. OPERAION, SAFETY, INSPECITON AND MAINTENANCE OF MACHINE . 814
1-2. OPERATION OF MONITORING SYSTEM . 814
1-3. CONSTANT POWER SUPPLY (BATERY DIRECT POWER SUPPLY) . 814
1-4. PRECAUTIONS AT THE TIME OF TURNING ON THE POWER FOR VHMS . 815
1-5. PRECAUTIONS AT THE TIME OF REPLACING VHMS AND TRANSMISSION CONTROLLER 815
1-6. OPERATION OF COMMUNICATION (ORB .ORB COMMUNICATION) CONTROLLER 816
2. OVERVIEW . 817
2-1. APPLICABLE MODEL . 817
2-2. BASIC CONFIGURATION 817
2-3. INSTALLATION DRAWING . 820
3. STRUCTURE AND FUNCTION . 822
3-1. VHMS CONTROLLER 822
3-2. BLOW-BY GAS SENSOR . 822
3-3. ENGINE OIL TEMPERAUTRE SENSOR 823
3-4. AMPLIFIER FOR EXHAUST GAS TEMPERATURE SENSOR . 824
3-5. COMMUNICATION (ORB .ORB COMMUNICATION) CONTROLLER/ANTENNA . 825
4. TROUBLESHOOTING 826
4-1. TROUBLESHOOTING EQUIPMENT LIST . 826
4-2. CONNECTOR TYPES AND MOUNTING LOCATIONS . 827
4-3. CONNECTOR ARRANGEMENT DIAGRAM 828
4-4. VHMS RELATED ELECTRICAL CIRCUIT DIAGRAM 833
4-5. ERROR CODE LIST 835
4-6. STANDARD VALUE TABLE FOR ELECTRICAL PARTS 836
4-7. TROUBLE PHENOMENA LIST . 837
HM-1: ABNORMALITY IN SATELLITE DATA TRANSMISSION 839
HM-2: ABNORMALITY IN DOWNLOADING OR SETTING WITH THE PC . 840
HM-3: MANUAL SNAP HAS NOT BEEN RECORDED . 841
HM-4: ABNORMAL BLOW-BY GAS PRESSURE . 842
HM-5: ABNORMAL EXHAUST GAS TEMPERATURE 843
HM-6: ABNORMAL ENGINE OIL TEMPERATURE . 844
HM-7: ABNORMAL ENGINE OIL PRESSURE 845
HM-8: ABNORMAL ENGINE SPEED . 846
HM-9: ABNORMAL FUEL INJECTION AMOUNT 847
HM-10: T/M DATE IS NOT DISPLAYED 848
HM-11: WHILE TRAVELLING, TRAVEL VALVE SUDDENLY BECOMES NEUTRAL AND CANNOT TRAVEL 848
5. SETTING OF VHMS CONTROLLER . 849
5-1. SETTING OF VHMS CONTROLLER . 849
5-2. SETTING ITEM . 849
5-3. SETTING FLOW (OUTLINE) . 849
5-4. CHECK OF OPERATION AND PERFORMANCE . 850
5-5. DATA COLLECTION 850
6. DATA RECOVERY AND TRANSMISSION . 851
6-1. DATA RECOVERY 851
7. INSPECTION AND MAINTENANCE . 858
7-1. INSPECTION TIMING: INSPECTION AND MAINTENANCE TIMING OF MACHINE 858
7-2. INSPECTION ITEM 858
7-3. CORRECTIVE ACTION 858
8. REPLACEMENT OF PARTS . 858
8-1. IF INITIAL SET-UP OF VHMS SYSTEM HAS BEEN MADE OR VHMS CONTROLLER HAS BEEN REPLACED 858
8-2. WHEN COMMUNICATION CONTROLLER IS REPLACED 858
PROCEDURE Ⅰ FOR INITIAL SETUP OF VHMS . 859
PROCEDURE Ⅱ FOR OPENING ORBCOMM SERVICE . 861
30 DISASSEMBLY AND ASSEMBLY . 865
METHOD OF USING MANUAL 867
PRECAUTIONS WHEN CARRYING OUT OPERATION . 868
SPECIAL TOOL LIST . 870
STARTING MOTOR 873
REMOVAL AND INSTALLATION 873
ALTERNATOR 874
REMOVAL AND INSTALLATION 874
ENGINE OIL COOLER . 875
REMOVAL AND INSTALLATION 875
AIR CONDITIONER COMPERSSOR 876
REMOVAL AND INSTALLATION 876
FUEL INJECTION PUMP . 877
REMOVAL . 877
INSTALLATION 878
AIR COMPRESSOR 879
REMOVAL AND INSTALLATION 879
AIR CONDITIONER COMPERSSOR 880
REMOVAL AND INSTALLATION 880
WATER PUMP 881
REMOVAL AND INSTALLATION 881
AFTERCOOLER CORE 882
REMOVAL AND INSTALLATION 882
EXHAUST BRAKE CYLINDER 883
REMOVAL AND INSTALLATION 883
TURBOCHARGER 884
REMOVAL AND INSTALLATION 884
NOZZLE HOLDER . 885
REMOVAL AND INSTALLATION 885
CYLINDER HEAD . 886
REMOVAL . 886
INSTALLATION 889
ENGINE 890
REMOVAL . 890
INSTALLATION 893
ENGINE FRONT SEAL . 894
REMOVAL AND INSTALLATION 894
ENGINE REAR SEAL 896
REMOVAL AND INSTALLATION 896
RADIATOR, TORQUE CONVERTER COOLER . 898
REMOVAL . 898
INSTALLTION . 900
BRAKE OIL COOLER 901
REMOVAL AND INSTALLATION 901
OUTPUT SHAFT 902
REMOVAL AND INSTALLATION 902
DISASSEMBLY . 904
ASSEMBLY 905
TORQUE CONVERTER, TRANSMISSION 907
REMOVAL . 907
INSTALLATION 908
PROCEDURE FOR CENTERING THE ENGINE ASSEMBLY AND TROQUE CONVERTER, TRANSMISSION ASSEMBLY . 909
TORQUE CONVERTER, CONTROL VALVE . 910
REMOVAL AND INSTALLATION 910
DISASSEMBLY AND ASSEMBLY 911
TORQUE CONVERTER AND TRANSMISSION . 912
DISCONNECTION . 912
CONNECTION 913
TORQUE CONVERTER, PTO . 914
DISASSEMBLY . 914
ASSEMBLY 920
TRANSMISSION 927
DISASSEMBLY . 927
ASSEMBLY 943
TRANSMISSION CONTROL VALVE (ECMV ASSEMBLY) 960
REMOVAL AND INSTALLATION 960
ECMV 961
DISASSEMBLY AND ASSEMBLY 961
DIFFERENTIAL . 963
REMOVAL AND INSTALLATION 963
DISASSEMBLY . 964
ASSEMBLY 968
FRONT WHEEL . 977
REMOVAL AND INSTALLATION 977
REAR WHEEL 978
REMOVAL 978
INSTALLATION 979
FRONT BRAKE CALIPER PAD . 980
REMOVAL AND INSTALLATION 980
FRONT BRAKE CALIPER . 981
REMOVAL AND INSTALLATION 981
DISASSEMBLY . 982
ASSEMBLY 983
FRONT WHEEL HUB . 985
DISASSEMBLY . 985
ASSEMBLY 987
FINAL DRIVE CARRIER . 990
REMOVAL AND INSTALLATION 990
DISASSEMBLY AND ASSEMBLY 991
FIANL DRIVE . 992
DISASSEMBLY . 992
ASSEMBLY 994
REAR BRAKE 996
REMOVAL AND INSTALLATION 996
DISASSEMBLY . 997
ASSEMBLY 998
PARKING BRAKE PAD .1000
REMOVAL .1000
INSTALLATION 1001
PARKING BRAKE CALIPER .1003
REMOVAL AND INSTALLATION 1003
DISASSEMBLY AND ASSEMBLY 1004
FRONT SUSPENSION CYLINDER .1005
REMOVAL AND INSTALLATION 1005
DISASSEMBLY .1007
ASSEMBLY 1008
VARIABLE DAMPING SELECTOR VALVE .1009
DISASSEMBLY .1009
ASSEMBLY 1010
REAR SUSPENSION CYLINDER 1011
REMOVAL AND INSTALLATION 1011
DISASSEMBLY .1012
ASSEMBLY 1013
AIR GOVERNOR 1014
REMOVAL AND INSTALLATION 1014
DISASSEMBLY AND ASSEMBLY 1015
BRAKE VALVE .1016
REMOVAL AND INSTALLATION 1016
DISASSEMBLY .1017
ASSEMBLY 1019
PARKING BRAKE CHAMBER .1021
REMOVAL AND INSTALLATION 1021
DISASSEMBLY .1022
ASSEMBLY 1023
FRONT BRAKE CHAMBER .1025
REMOVAL AND INSTALLATION 1025
DISASSEMBLY .1026
ASSEMBLY 1028
REAR BRAKE CHAMBER 1025
REMOVAL AND INSTALLATION 1025
DISASSEMBLY .1030
ASSEMBLY 1033
SLACK ADJUSTER 1036
REMOVAL AND INSTALLATION 1036
DISASSEMBLY AND ASSEMBLY 1037
TRANSMISSION LUBRICATION, RETARDER BRAKE PUMP 1038
REMOVAL AND INSTALLATION 1038
BRAKE COOLING PUMP 1039
REMOVAL AND INSTALLATION 1039
HOIST, STEERING PUMP 1039
REMOVAL AND INSTALLATION 1039
EMERGENCY STEERING MOTOR PUMP .1040
REMOVAL AND INSTALLATION 1040
BRAKE CONTROL VALVE .1041
REMOVAL AND INSTALLATION 1041
STEERING VALVE 1042
REMOVAL AND INSTALLATION 1042
DISASSEMBLY .1043
ASSEMBLY 1047
DEMAND VALVE 1054
REMOVAL AND INSTALLATION 1054
DISASSEMBLY AND ASSEMBLY 1055
RELIEF VALVE 1056
DISASSEMBLY AND ASSEMBLY 1056
HOIST VALVE .1057
REMOVAL AND INSTALLATION 1057
DISASSEMBLY .1058
ASSEMBLY 1059
STEERING CYLINDER .1060
REMOVAL AND INSTALLATION 1060
DISASSEMBLY .1061
ASSEMBLY 1063
HOIST CYLINDER 1065
REMOVAL AND INSTALLATION 1065
DISASSEMBLY .1066
ASSEMBLY 1067
BODY 1068
REMOVAL .1068
INSTALLATION 1069
TRANSMISSION CONTROLLER .1070
REMOVAL AND INSTALLATION 1070
SUSPENSION CONTROLLER .1070
REMOVAL AND INSTALLATION 1070
40 MAINTENANCE STANDARD .1071
OUTPUT SHAFT 1072
TURQUE CONVERTER VALVE 1073
TORQUE CONVERTER 1074
TRANSMISSION 1076
ECMV 1080
FRONT AXLE 1081
REAR AXLE SUPPORT .1082
DIFFERENTIAL 1083
FINAL DRIVE .1084
FRONT BRAKE .1085
REAR BRAKE 1086
PARKING BRAKE .1087
STEERING LINKAGE 1088
FRONT SUSPENSION CYLINDER .1090
REAR SUSPENSION CYLINDER 1091
PARKING BRAKE CHAMBER .1092
SLACK ADJUSTER 1093
HYDRAULIC PUMP .1094
DEMAND VALVE 1097
CROSS-OVER RELIEF VALVE .1097
HOIST VALVE .1098
STEERING CYLINDER .1099
HOIST CYLINDER 1100
90 OTHERS .1101
ELECTRICAL CIRCUIT DIAGRAM .1102
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (1/3) .1102
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (2/3) .1103
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (3/3) .1104
ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (1/2) 1105
ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (2/2) 1106
ELECTRICAL CONTROL SYSTEM .1107
ELECTRICAL CIRCUIT DIAGRAM 1107
AUTOMATIC RETARD SPEED CONTROL SYSTEM .1108
ELECTRICAL CIRCUIT DIAGRAM 1108
AUTOMATIC SHIFT CONTROL SYSTEM 1109
ELECTRICAL CIRCUIT DIAGRAM 1109
AUTOMATIC SUSPENSION SYSTEM .1110
SYSTEM CIRCUIT DIAGRAM (1/2) 1110
SYSTEM CIRCUIT DIAGRAM (2/2) 1111
PAYLOAD METER (PRINTER TYPE) 1112
ELECTRICAL CIRCUIT DIAGRAM 1112
PAYLOAD METER Ⅱ (CARD TYPE) .1113
ELECTRICAL CIRCUIT DIAGRAM 1113
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM .1114
VHMS MACHINE HEALTH DIAGNOSIS SYSTEM (OPT) 1115
1. BASIC PRECAUTIONS 1116
1-1. OPERAION, SAFETY, INSPECITON AND MAINTENANCE OF MACHINE .1116
1-2. OPERATION OF MONITORING SYSTEM .1116
1-3. CONSTANT POWER SUPPLY (BATERY DIRECT POWER SUPPLY) .1116
1-4. PRECAUTIONS AT THE TIME OF TURNING ON THE POWER FOR VHMS .1117
1-5. PRECAUTIONS AT THE TIME OF REPLACING VHMS AND TRANSMISSION CONTROLLER 1117
1-6. OPERATION OF COMMUNICATION (ORB .ORB COMMUNICATION) CONTROLLER 1118
2. OVERVIEW .1119
2-1. APPLICABLE MODEL .1119
2-2. BASIC CONFIGURATION 1119
2-3. INSTALLATION DRAWING .1122
3. STRUCTURE AND FUNCTION .1124
3-1. VHMS CONTROLLER 1124
3-2. BLOW-BY GAS SENSOR .1124
3-3. ENGINE OIL TEMPERAUTRE SENSOR 1125
3-4. AMPLIFIER FOR EXHAUST GAS TEMPERATURE SENSOR .1126
3-5. COMMUNICATION (ORB .ORB COMMUNICATION) CONTROLLER/ANTENNA .1127
4. TROUBLESHOOTING 1128
4-1. TROUBLESHOOTING EQUIPMENT LIST .1128
4-2. CONNECTOR TYPES AND MOUNTING LOCATIONS .1129
4-3. CONNECTOR ARRANGEMENT DIAGRAM 1130
4-4. VHMS RELATED ELECTRICAL CIRCUIT DIAGRAM 1135
4-5. ERROR CODE LIST 1137
4-6. STANDARD VALUE TABLE FOR ELECTRICAL PARTS 1138
4-7. TROUBLE PHENOMENA LIST .1139
HM-1: ABNORMALITY IN SATELLITE DATA TRANSMISSION 1141
HM-2: ABNORMALITY IN DOWNLOADING OR SETTING WITH THE PC .1142
HM-3: MANUAL SNAP HAS NOT BEEN RECORDED .1143
HM-4: ABNORMAL BLOW-BY GAS PRESSURE .1144
HM-5: ABNORMAL EXHAUST GAS TEMPERATURE 1145
HM-6: ABNORMAL ENGINE OIL TEMPERATURE .1146
HM-7: ABNORMAL ENGINE OIL PRESSURE 1147
HM-8: ABNORMAL ENGINE SPEED .1148
HM-9: ABNORMAL FUEL INJECTION AMOUNT 1149
HM-10: T/M DATE IS NOT DISPLAYED 1150
HM-11: WHILE TRAVELLING, TRAVEL VALVE SUDDENLY BECOMES NEUTRAL AND CANNOT TRAVEL 1150
5. SETTING OF VHMS CONTROLLER .1151
5-1. SETTING OF VHMS CONTROLLER .1151
5-2. SETTING ITEM .1151
5-3. SETTING FLOW (OUTLINE) .1151
5-4. CHECK OF OPERATION AND PERFORMANCE .1152
5-5. DATA COLLECTION 1152
6. DATA RECOVERY AND TRANSMISSION .1153
6-1. DATA RECOVERY 1153
7. INSPECTION AND MAINTENANCE .1160
7-1. INSPECTION TIMING: INSPECTION AND MAINTENANCE TIMING OF MACHINE 1160
7-2. INSPECTION ITEM 1160
7-3. CORRECTIVE ACTION 1160
8. REPLACEMENT OF PARTS .1160
8-1. IF INITIAL SET-UP OF VHMS SYSTEM HAS BEEN MADE OR VHMS CONTROLLER HAS BEEN REPLACED 1160
8-2. WHEN COMMUNICATION CONTROLLER IS REPLACED 1160
PROCEDURE Ⅰ FOR INITIAL SETUP OF VHMS .1161
PROCEDURE Ⅱ FOR OPENING ORBCOMM SERVICE .1163

DESCRIPTION:

Komatsu HD465-5,HD605-5 Dump Truck Shop Manual SEBM015208  – PDF DOWNLOAD

MACHINE MODEL           SERIAL NUMBER

• HD465-5                            4626 and up
• HD605-5                            1013 and up

G.B 28/12/24