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KOMATSU HD465-5,HD605-5 Rigid Dump Truck Service Repair Workshop Manual – PDF DOWNLOAD
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Description
KOMATSU HD465-5,HD605-5 Rigid Dump Truck Service Repair Workshop Manual
FILE DETAILS:
KOMATSU HD465-5,HD605-5 Rigid Dump Truck Service Repair Workshop Manual
Brands: Komatsu
Equipment Type: Dump Truck
Manuals Type: Shop Manual
Machine Model: HD465-5,HD605-5
Serial Number: 4626, 1013 and up
Book Code: SEBM015209
Language: English
Pages: 1206
File Format: Portable Document Format (PDF)
DESCRIPTION:
KOMATSU HD465-5,HD605-5 Rigid Dump Truck Service Repair Workshop Manual
1 GENERAL:
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
GENERAL:
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section gives the judgement standards when inspecting disassembled parts.
STANDARD VALUE TABLE:
This section explains the standard values for new machine and judgement criteria for testing, adjusting and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs.
TROUBLESHOOTING:
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
OTHERS:
This section has the foldout drawings for the machine.
TABLE OF CONTENTS:
KOMATSU HD465-5,HD605-5 Rigid Dump Truck Service Repair Workshop Manual
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 DESICCANT TYPE AIR DRIER...................................................................................................................................................................................................................................................... 88 AIR GOVERNOR.................................................................................................................................................................................................................................................................. 89 SAFETY VALVE.................................................................................................................................................................................................................................................................. 89 CHECK VALVE................................................................................................................................................................................................................................................................... 90 DOUBLE CHECK VALVE............................................................................................................................................................................................................................................................ 90 AUTO DRAIN VALVE.............................................................................................................................................................................................................................................................. 91 HAND BRAKE VALVE.............................................................................................................................................................................................................................................................. 92 BRAKE VALVE................................................................................................................................................................................................................................................................... 93 REDUCING VALVE................................................................................................................................................................................................................................................................ 94 EMERGENCY BRAKE CONTROL VALVE................................................................................................................................................................................................................................................. 96 PARKING BRAKE CONTROL VALVE................................................................................................................................................................................................................................................... 99 RELAY VALVE................................................................................................................................................................................................................................................................... 100 PARKING BRAKE RELAY VALVE..................................................................................................................................................................................................................................................... 103 QUICK-RELEASE VALVE........................................................................................................................................................................................................................................................... 105 PARKING BRAKE CHAMBER......................................................................................................................................................................................................................................................... 105 FRONT BRAKE CHAMBER........................................................................................................................................................................................................................................................... 106 REAR BRAKE CHAMBER............................................................................................................................................................................................................................................................ 107 SLACK ADJUSTER................................................................................................................................................................................................................................................................ 110 AIR DRIER (DESICCANT TYPE).................................................................................................................................................................................................................................................... 111 HYDRAULIIC PIPING ............................................................................................................................................................................................................................................................ 113 HYDRAULIC CIRCUIT DIAGRAM .................................................................................................................................................................................................................................................... 115 DUMP BODY CONTROL............................................................................................................................................................................................................................................................. 116 HYDRAULIC TANK AND BRAKE COOLING OIL TANK..................................................................................................................................................................................................................................... 117 BRAKE COOLING OIL CONTROL VALVE(BCV).......................................................................................................................................................................................................................................... 118 STEERING CONTROL VALVE........................................................................................................................................................................................................................................................ 119 DEMAND VALVE.................................................................................................................................................................................................................................................................. 123 CROSS-OVER RELIEF VALVE....................................................................................................................................................................................................................................................... 127 HOIST VALVE................................................................................................................................................................................................................................................................... 128 STEERING CYLINDER............................................................................................................................................................................................................................................................. 130 HOIST CYLINDER................................................................................................................................................................................................................................................................ 130 ELECTRICAL CIRCUIT DIAGAM..................................................................................................................................................................................................................................................... 131 STOP LAMP SWITCH.............................................................................................................................................................................................................................................................. 136 EXHAUST BRAKE SWITCH.......................................................................................................................................................................................................................................................... 136 FRONT BRAKE CUT-OFF VALVE..................................................................................................................................................................................................................................................... 137 OVERRUN PREVENTION VALVE...................................................................................................................................................................................................................................................... 138 EXHAUST BRAKE VALVE........................................................................................................................................................................................................................................................... 138 HORN VALVE.................................................................................................................................................................................................................................................................... 139 PARKING BRAKE SWITCH.......................................................................................................................................................................................................................................................... 139 AIR CONDIYIONER............................................................................................................................................................................................................................................................... 140 PIPING DIAGRAM............................................................................................................................................................................................................................................................ 140 ELECTRICAL CIRCUIT DIAGRAM................................................................................................................................................................................................................................................ 141 REFRIGERANT CIRCUIT DIAGRAM............................................................................................................................................................................................................................................... 143 UNIT...................................................................................................................................................................................................................................................................... 144 RECEIVER DRYER............................................................................................................................................................................................................................................................ 145 CONDENSER................................................................................................................................................................................................................................................................. 145 COMPRESSOR................................................................................................................................................................................................................................................................ 146 ENGINE CONTROL SYSTEM ........................................................................................................................................................................................................................................................ 147 SYSTEM DRAWING............................................................................................................................................................................................................................................................ 147 AISS...................................................................................................................................................................................................................................................................... 148 FUEL INJECTION PUMP ELECTRONIC GOVERNOR................................................................................................................................................................................................................................... 149 HYDRAULIC CIRCUIT DIAGRAM................................................................................................................................................................................................................................................. 150 ENGINE CONTROLLER......................................................................................................................................................................................................................................................... 151 SENSORS, SWITCHES......................................................................................................................................................................................................................................................... 151 ELECTRICAL CIRCUIT DIAGRAM................................................................................................................................................................................................................................................ 152 APS........................................................................................................................................................................................................................................................................... 153 EXHAUST BRAKE................................................................................................................................................................................................................................................................. 155 SYSTEM DIAGRAM............................................................................................................................................................................................................................................................ 155 SYSTEM CIRCUIT DIAGRAM.................................................................................................................................................................................................................................................... 156 AUTOMATIC RETARD SPEED CONTROL SYSTEM......................................................................................................................................................................................................................................... 158 SYSTEM DRAWING............................................................................................................................................................................................................................................................ 158 STRUCTURE OF SYSTEM....................................................................................................................................................................................................................................................... 159 ELECTRICAL CIRCUIT DIAGRAM................................................................................................................................................................................................................................................ 160 AIR CIRCUIT DIAGRAM....................................................................................................................................................................................................................................................... 161 AUTOMATIC RETARD SPEED CONTROL............................................................................................................................................................................................................................................ 162 AUTOMATIC RETARD SPEED CONTROLLER......................................................................................................................................................................................................................................... 163 AUTOMATIC SHIFT CONTROL SYSYTEM............................................................................................................................................................................................................................................... 164 SYSTEM DIAGRAM............................................................................................................................................................................................................................................................ 164 ELECTRICAL CIRCUIT DIAGRAM................................................................................................................................................................................................................................................ 166 TRANSMIAAION CONTROLLER................................................................................................................................................................................................................................................... 167 CONNECTOR SIGNALS......................................................................................................................................................................................................................................................... 168 SELF-DIAGNOSTIC FUNCTION.................................................................................................................................................................................................................................................. 168 SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFTING RANGES.................................................................................................................................................................................................................. 169 AUTOMATIC GEAR SHIFTING LINE GRAPH........................................................................................................................................................................................................................................ 170 SHIFT LEVER SWITCH........................................................................................................................................................................................................................................................ 173 SENSORS, SWITCHES......................................................................................................................................................................................................................................................... 174 ENGINE SPEED SENSOR................................................................................................................................................................................................................................................... 174 TRANSMISSION SPEED SENSOR............................................................................................................................................................................................................................................. 174 TRANSMISSION OIL TEMPERATURE SENSOR................................................................................................................................................................................................................................... 174 FILL SWITCH........................................................................................................................................................................................................................................................... 175 ACCELERATOR SENSOR.................................................................................................................................................................................................................................................... 176 SHIFT LIMIT SWITCH.................................................................................................................................................................................................................................................... 177 MODE SELECTOR SWITCH.................................................................................................................................................................................................................................................. 177 AUTOMATIC EMERGENCY STEERING SYSTEM........................................................................................................................................................................................................................................... 178 SYSTEM DIAGRAM............................................................................................................................................................................................................................................................ 178 ELECTRICAL CIRCUIT DIAGRAM................................................................................................................................................................................................................................................ 179 FLOW SWITCH............................................................................................................................................................................................................................................................... 180 RELAY TIMER............................................................................................................................................................................................................................................................... 182 AUTOMATIC SUSPENSION SYSTEM................................................................................................................................................................................................................................................... 183 STRUCTURE OF SYSTEM....................................................................................................................................................................................................................................................... 184 SYSTEM CIRCUIT DIAGRAM.................................................................................................................................................................................................................................................... 185 AUTOMATIC SUSPENSION MODE SELECTION CONTROL............................................................................................................................................................................................................................... 186 SUSPENSION CONTROLLER..................................................................................................................................................................................................................................................... 187 SENSORS, SWITCHES......................................................................................................................................................................................................................................................... 188 STEERING ANGLE SENSOR................................................................................................................................................................................................................................................. 188 PRESSURE SENSOR....................................................................................................................................................................................................................................................... 188 SELF-DIAGNOSTIC FUNCTION.............................................................................................................................................................................................................................................. 189 PAYLOAD METER (PRINTER TYPE).................................................................................................................................................................................................................................................. 190 STRUCTURE OF SYSTEM....................................................................................................................................................................................................................................................... 190 ELECTRICAL CIRCUIT DIAGRAM................................................................................................................................................................................................................................................ 191 PRINCIPLE OF CALCULATION.................................................................................................................................................................................................................................................. 192 FEATURES OF EQUIPMENT..................................................................................................................................................................................................................................................... 194 1. PAYLOAD METER...................................................................................................................................................................................................................................................... 194 2. PRESSURE SENSOR.................................................................................................................................................................................................................................................... 197 3. CLINOMETER......................................................................................................................................................................................................................................................... 198 4. LAMP DRIVE RELAY................................................................................................................................................................................................................................................... 198 SELF-DIAGNOSTIC FUNCTION.................................................................................................................................................................................................................................................. 199 PAYLOAD METER Ⅱ (CARD TYPE)................................................................................................................................................................................................................................................... 200 STRUCTURE OF SYSTEM....................................................................................................................................................................................................................................................... 200 ELECTRICAL CIRCUIT DIAGRAM................................................................................................................................................................................................................................................ 201 PRINCIPLE OF MEASUREMNT................................................................................................................................................................................................................................................... 202 FEATURES OF EACH DEVICE................................................................................................................................................................................................................................................... 203 1. PAYLOAD METER Ⅱ.................................................................................................................................................................................................................................................... 203 LEFT FACE............................................................................................................................................................................................................................................................. 204 2. PRESSURE SENSOR.................................................................................................................................................................................................................................................... 231 3. CLINOMETER......................................................................................................................................................................................................................................................... 232 4. LAMP DRIVE RELAY................................................................................................................................................................................................................................................... 232 5. SELF-DIAGNOSTIC FUNCTION........................................................................................................................................................................................................................................... 233 MACHINE MONITOR SYSTEM........................................................................................................................................................................................................................................................ 239 SYSTEM DRAWING............................................................................................................................................................................................................................................................ 239 MONITOR PANEL DIAGRAM..................................................................................................................................................................................................................................................... 241 MACHINE MONITOR NORMAL DISPLAY FUNCTIONS.................................................................................................................................................................................................................................. 242 SELF-DIAGNOSTIC FUNCTION WHEN STARTING SWITCH IS OPERATED................................................................................................................................................................................................................. 249 TRAVEL SPEED COMPENSATION ROTARY SWITCH................................................................................................................................................................................................................................... 249 SENSORS,SWITCHES.......................................................................................................................................................................................................................................................... 250 ENGINE OIL PRESSURE................................................................................................................................................................................................................................................... 250 FUEL LEVEL SENSOR..................................................................................................................................................................................................................................................... 251 ENGINE WATER TEMPERATURE SENSOR....................................................................................................................................................................................................................................... 252 RETARDER OIL TEMOERATURE SENSOR....................................................................................................................................................................................................................................... 252 TORQUE CONVERTER OIL TEMPERATURE SENSOR............................................................................................................................................................................................................................... 252 AIR PRESSURE SENSOR................................................................................................................................................................................................................................................... 252 RADIATOR WATER LEVEL SENSOR........................................................................................................................................................................................................................................... 253 TRANSMISSION OIL FILTER SENSOR........................................................................................................................................................................................................................................ 253 STEERING OIL TEMPERATURE SENSOR ...................................................................................................................................................................................................................................... 254 BRAKE STROKE SENSOR................................................................................................................................................................................................................................................... 254 BODY SEATED SWITCH ................................................................................................................................................................................................................................................... 255 TILT SWITCH................................................................................................................................................................................................................................................................... 256 20 TESTING AND ADJUSTING.......................................................................................................................................................................................................................................................... 257 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS................................................................................................................................................................................................................................. 258 STANDARD VALUE TABLE FOR CHASSIS.............................................................................................................................................................................................................................................. 259 STANDARD VALUE TABLE FOR ELECTRICAL PARTS..................................................................................................................................................................................................................................... 264 TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.................................................................................................................................................................................................................... 275 ADJUSTING VALVE CLEARANCE..................................................................................................................................................................................................................................................... 277 MEASURING COMPRESSION PRESSURE................................................................................................................................................................................................................................................ 278 MEASURING BLOW-BY............................................................................................................................................................................................................................................................. 279 ADJUSTING FUEL INJECTION TIMING............................................................................................................................................................................................................................................... 280 BLEEDING AIR FROM FUEL-INJECTION PUMP......................................................................................................................................................................................................................................... 282 ADJUSTING ENGINE STOP MOTOR CABLE............................................................................................................................................................................................................................................. 283 ADJUSTING ACCELERATOR PEDAL................................................................................................................................................................................................................................................... 284 ADJUSTING ENGINE,TRANSIMSSION SPEED SENSORS................................................................................................................................................................................................................................... 285 TESTING HYDRAULIC PRESSURE OF TORQUE CONVERTER VALVE.......................................................................................................................................................................................................................... 286 TESTING ECMV HYDRAULIC PRESSURE............................................................................................................................................................................................................................................... 287 TESTING TORQUE CONVERTER STALL SPEED.......................................................................................................................................................................................................................................... 290 TESTING BRAKE PRESSURE........................................................................................................................................................................................................................................................ 292 BLEEDING AIR FROM BRAKE CIRCUIT............................................................................................................................................................................................................................................... 293 TESTING AND ADJUSTING PARKING BRAKE PERFORMANCE............................................................................................................................................................................................................................... 294 TESTING WEAR OF FRONT BRAKE PAD............................................................................................................................................................................................................................................... 295 TESTING WEAR OF REAR BRAKE DISC............................................................................................................................................................................................................................................... 296 TESTING AND ADJUSTING SUSPENSION CYLINDER..................................................................................................................................................................................................................................... 297 TESTING AND ADJUSTING AIR PRESSURE IN AIR CIRCUIT............................................................................................................................................................................................................................. 303 INSPECTION OF AIR DRIER (DESICCANT TYPE)...................................................................................................................................................................................................................................... 304 ADJUSTING HOIST LEVER LINKAGE................................................................................................................................................................................................................................................. 306 ADJUSTING BODY POSITIONER..................................................................................................................................................................................................................................................... 307 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING, HOIST CIRCUIT........................................................................................................................................................................................................... 308 AIR BLEEDING FROM STEERING CYLINDER........................................................................................................................................................................................................................................... 310 ADJUSTING ELECTRONIC MONITOR ................................................................................................................................................................................................................................................. 311 ADUSTING Q [FUEL INJECTION AMOUNT] WHEN REPLACING ENGINE CONTROLLER........................................................................................................................................................................................................... 312 SETTING ROTARY SWITCH WHEN REPLACING TRANSMISSION CONTROLLER.................................................................................................................................................................................................................. 313 METHOD OF DELETING DATA FROM ENGINE CONTROLLER, TRANSMISSION CONTROLLER MEMORY(CONTROL FROM MONITOR PANEL).................................................................................................................................................................... 314 METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM........................................................................................................................................................................................................ 317 PROCEDURE FOR OPERATING MODULATION CHECKER.................................................................................................................................................................................................................................... 323 PERFORMONG PM CLINIC USING MANUAL SNAPSHOT(=QUICK PM)......................................................................................................................................................................................................................... 328 PM-CLINIC SERVICE............................................................................................................................................................................................................................................................. 332 TROUBLESHOOTING............................................................................................................................................................................................................................................................... 334 POINTS TO REMEMBER WHEN TROUBLESHOOTNG.................................................................................................................................................................................................................................... 335 SEQUENCE OF EVENTS IN TROUBLESHOOTING..................................................................................................................................................................................................................................... 336 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.......................................................................................................................................................................................................................... 337 CHECKS BEFORE TROUBLESHOOTING............................................................................................................................................................................................................................................. 345 TYPE OF CONNECTOR AND POSITION OF INSTALLATION............................................................................................................................................................................................................................ 347 CONNECTOR PIN ALLOCATION CHART............................................................................................................................................................................................................................................ 352 CONNECTION TABLE FOR CONNECTOR PIN NUKBERS................................................................................................................................................................................................................................ 357 EXPLANATIONS OF FUNCTIONS (CONTROL MECHANISM) OF ELECTRICAL SYSTEM........................................................................................................................................................................................................ 384 MONITOR PANEL USER COSDES AND SERVICE MODE FUNCTION....................................................................................................................................................................................................................... 389 SELF-DIAGNOSTIC DISPLAY METHOD FOR MONITOR PANEL AND CONTROLLERS.......................................................................................................................................................................................................... 405 TABLE OF SERVICE CODES AND USER CODES..................................................................................................................................................................................................................................... 412 METHOD OF USING JUDGMENT TABLE............................................................................................................................................................................................................................................ 422 METHOD OF USING TROUBLESHOOTING CHARTS.................................................................................................................................................................................................................................... 423 TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (ELECTRONIC GOVERNOR SPECIFICATION G MODE).................................................................................................................................................................................... 425 ACTION TAKEN BY SELF-DIAGNOSTIC AND PROB-LEMS ON MACHINE.............................................................................................................................................................................................................. 426 JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER, TRANSMISSION RELATED PARTS............................................................................................................................................................................................... 434 G-1 [0.0] (OFF) OR C010 [E.<-->1.0] ABNORMALITY IN POWER SOURCE....................................................................................................................................................................................................... 438 G-2 C011 [E.<-->1.1] ABNORMALITY IN CONTROLLER........................................................................................................................................................................................................................ 438 G-3 C012 [E.<-->1.2] ABNORMALITY IN RACK SENSOR SYSTEM................................................................................................................................................................................................................ 439 G-4 C014 [E.<-->1.4] ABNORMALITY IN GOVERNOR SOLENOID SYSTEM.......................................................................................................................................................................................................... 440 G-5 C016 [E.<-->1.6] ABNORMALITY IN GOVERNOR CUT RELAY SYSTEM......................................................................................................................................................................................................... 441 G-6 C018 [E.<-->1.8] ABNORMALITY IN RACK SENSOR POWER SOURCE SYSTEM................................................................................................................................................................................................... 442 G-7 C019 [E.<-->1.9] ABNORMALITY IN GOVERNOR SERVO SYSTEM BANK ....................................................................................................................................................................................................... 443 G-8 C01b [E.<-->1.6] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM A...................................................................................................................................................................................................... 444 G-9 C01c [E.<-->1.C] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM B...................................................................................................................................................................................................... 445 G-10 C01d [E.<-->1.d] ABNORMALITY IN PRE-STROKE SOLENOID SYSTEM....................................................................................................................................................................................................... 446 G-11 C021 [E.<-->2.1] MISTAKEN CONNECTION OF CONNECTOR................................................................................................................................................................................................................ 447 G-12 C022 [E.<-->2.2] ENGINE OVERRUN.................................................................................................................................................................................................................................. 448 G-13 C023 [E.<-->2.3] ENGINE OVERHEATING.............................................................................................................................................................................................................................. 448 G-14 C024 [E.<-->2.4] DROP IN ENGINE OIL PRESSURE..................................................................................................................................................................................................................... 448 G-15 C031 [E.<-->3.1] ABNORMALITY IN ACCELERATON SENSOR SYSTEM ....................................................................................................................................................................................................... 449 G-16 C034 [E.<-->3.4] ABNORMALITY IN ENGINE WATER TEMPERATURE SYETEM ................................................................................................................................................................................................. 452 G-17 C036 [E.<-->3.6] ABNORMALITY IN ENGINE OIL PRESSURE SENSOR ...................................................................................................................................................................................................... 453 G-18 C055 [E.<-->5.5] ABNORMALITY IN NETWORK.......................................................................................................................................................................................................................... 454 G-19 C056 [E.<-->5.6] ABNORMALITY IN SOLENOID POWER SOURCE SYSTEM RIGHT............................................................................................................................................................................................... 455 G-20 C058 [E.<-->5.8] ABNORMALITY IN BACKUP POWER SOURCE SYSTEM ...................................................................................................................................................................................................... 456 G-21 C059 [E.<-->5.9] ABNORMALITY IN BACKUP SOURCE SYSTEM............................................................................................................................................................................................................. 457 G-22 C0C2 [E.<-->C.2] DEFECTIVE MODEL SELECTION DATA.................................................................................................................................................................................................................. 458 G-23 C0C4 [E.<-->C.4] ABNORAMLITY IN ACCELERATION SENSOR SYSTEM....................................................................................................................................................................................................... 459 G-24 C0C5 [E.<-->C.5] ABNORAMLITY IN IDLING VALIDATION................................................................................................................................................................................................................ 462 G-25 ENGINE DOES NOT START............................................................................................................................................................................................................................................ 464 G-26 DEFECTIVE ACTUATION OF APS....................................................................................................................................................................................................................................... 467 TROUBLESHOOTING OF ENGINE SYSTEM (S MODDE)................................................................................................................................................................................................................................ 475 METHOD OF USING TROUBLESHOOTING CHART................................................................................................................................................................................................................................. 476 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)......................................................................................................................................................................................................... 480 S-2 ENGINE DOES NOT START............................................................................................................................................................................................................................................. 482 a) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT(FUEL IS NOT BEING INJECTED)........................................................................................................................................................................................ 482 b) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START(FUEL IS BEING INJECTED)...................................................................................................................................................................................... 483 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR).............................................................................................................................................................................................................. 484 S-4 ENGINE STOPS DURING OPERATIONS.................................................................................................................................................................................................................................... 485 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)......................................................................................................................................................................................................................... 487 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER).............................................................................................................................................................................................................................. 488 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTON)..................................................................................................................................................................................................................... 489 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE............................................................................................................................................................................................................ 490 S-9 OIL BECOMES CONTAMINATED QUICKLY.................................................................................................................................................................................................................................. 491 S-10 FUEL CONSUMPTION IS EXCESSIVE.................................................................................................................................................................................................................................... 492 S-11 OIL IS COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN............................................................................................................................................................................................. 493 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)....................................................................................................................................................................................................... 494 S-13 OIL LEVEL RISES.................................................................................................................................................................................................................................................. 495 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)................................................................................................................................................................................................................. 496 S-15 ABNORMAL NOISE IS MADE........................................................................................................................................................................................................................................... 497 S-16 VIBRATION IS EXCESSIVE........................................................................................................................................................................................................................................... 499 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A MODE)................................................................................................................................................................................................................ 500 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM................................................................................................................................................................................ 503 ACTION TAKEN BY SELF-DIAGNOSTIC AND PROBLEMS ON MACHINE............................................................................................................................................................................................................... 505 JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER, TRANSMISSION RELATED PARTS............................................................................................................................................................................................... 525 ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM......................................................................................................................................................................................................... 527 A-1 ABNORMALITY IN POWER SOURCE SYSTEM................................................................................................................................................................................................................................ 528 a) [u.u] [OFF] CONTROLLER SELF-DIAGNOSTIC DISPLAY LED DOES NOT LIGHT UP........................................................................................................................................................................................... 528 b) bOO1 [E. <-->0.1, E.C<-->0.1] DROP IN VOLTAGE OF CONTROLLER POWER SOURCE IS DISPLAYED.......................................................................................................................................................................... 529 c) bOdA [E. <-->d.A, E.C<-->d.A] DROP IN VOLTAGE OF BATTERY DIRECT POWER SOURCE IS DISPLAYED...................................................................................................................................................................... 530 d) bOdb [E. <-->d.b, E.C<-->d.b] DROP IN VOLTAGE OF MAIL POWER SOURCE IS DISPLAYED................................................................................................................................................................................ 531 e) bOO2 [E. <-->0.2, E.C<-->0.2] ABNORMALITAY IN TRANSMISSION CUT RELAY POWER SOURCE IS DISPLAYED................................................................................................................................................................. 532 A-2 bOO3 [E. <-->0.3, E.C<-->0.3] ABNORMALITY IN NEUTRAL SAFETY SYSTEM IS DISPLAYED................................................................................................................................................................................... 533 A-3 bOO5 [E. <-->0.5, E.C<-->0.5] DOUBLE ENGAGEMENT FOR CLUTCH IS DISPLAYED........................................................................................................................................................................................... 534 A-4 bOO6 [E. <-->0.6, E.C<-->0.6] ABNORMALITY IN TRANSMISSION [CUT RELAY] SYSTEM DISPLAYED............................................................................................................................................................................ 535 A-5 bOO8 [E. <-->0.8, E.C<-->0.8] ABNORMALITY IN REAR BRAKE SOLENOID SYSTEM IS DISPLAYED.............................................................................................................................................................................. 536 A-6 bOO9 [E. <-->0.9,E.C<-->0.9] ABNORMALITY IN EXHAUST BRAKE SOLENOID SYSTEM IS DISPLAYED............................................................................................................................................................................ 537 A-7 .................................................................................................................................................................................................................................................................. 538 a) bOC4 [E. <-->C.4, E.C<-->C.4] SHORT CIRCUIT WITH GROUND IN BCV REAR SOLENOID IS DISPLAYED...................................................................................................................................................................... 538 b) bOC6 [E. <-->C.6, E.C<-->C.6] SHORT CIRCUIT IN BCV REAR SOLENOID IS DISPLAYED.................................................................................................................................................................................. 539 c) bOC8 [E. <-->C.8, E.C<-->C.8] DISCONNECTION IN BCV REAR SOLENOID IS DISPLAYED.................................................................................................................................................................................. 540 A-8 ABNORMALITY IN SPEED SENSOR SYSTEM ............................................................................................................................................................................................................................... 541 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).... 541 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............................................................................... 542 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................................................................. 543 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............................................ 544 A-9 SPEED SENSOR SYSTEM, CLUTCH SLIPPING.............................................................................................................................................................................................................................. 545 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...................................................................................................................................... 545 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..................................................................................................................... 546 A-10 ABNORMALITY IN MODEL SELECTION (WIRING HARNESS) IS DISPLAYED..................................................................................................................................................................................................... 547 a) b014 [E. <-->1.4, E.C<-->1.4] ABNORMALITY IN MODEL SELECTION(WIRING HARNESS)IS DISPLAYED....................................................................................................................................................................... 547 b) b0A1 [E. <-->A.1, E.C<-->A.1] ABNORMALITY IN MODEL SELECTION(ROTARY SWITCH)IS DISPLAYED........................................................................................................................................................................ 548 A-11 ABNORMALITY IN SHIFT LEVER SYSTEM................................................................................................................................................................................................................................ 549 a) b007 [E. <-->0.7, E.C<-->0.7] SHORT CIRCUIT IN SHIFT LEVER ASSEMBLY POWER SOURCE IS DISPLAYED.................................................................................................................................................................. 549 b) b015 [E. <-->1.5, E.C<-->1.5] SHIFT LEVER POSITION SIGNAL INPUT FOR 2 OR MORE SYSTEM IS DISPLAYED.............................................................................................................................................................. 550 c) b016 [E. <-->1.6, E.C<-->1.6] SHIFT LEVER POSITION SIGNAL IS NOT INPUT......................................................................................................................................................................................... 552 A-12 b017 [E. <-->1.7, E.C<-->1.7] ABNORMALITY IN ACCELERATOR SIGNAL IS DISPLAYED..................................................................................................................................................................................... 554 A-13 b019 [E. <-->1.9, E.C<-->1.9] ABNORMALITY IN TRANSMISSION OIL TRMPERATURE SENSOR IS DISPLAYED.................................................................................................................................................................... 555 A-14 ABNORMALITY IN PRESSURE CONTROL VALVE SYSTEM..................................................................................................................................................................................................................... 556 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.......................................................................................................................................... 556 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........................................................................................................................................ 558 b-1) INSPECTING FILL SIGNAL SYSTEM............................................................................................................................................................................................................................ 558 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)................................................................................................ 559 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)....................................................................................... 559 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).......................................................................................................................................... 560 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............................................................................................................................... 561 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............................................................................................................................... 561 A-17 ABNORMALITY IN SENSOR SYSTEM..................................................................................................................................................................................................................................... 563 a) b0A2 [E. <-->A.2, E.C<-->A.2] ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE SENSOR SYSTEM IS DISPLAYED....................................................................................................................................................... 563 b) b0A3 [E. <-->A.3, E.C<-->A.3] ABNORMALITY IN FUEL LEVEL SENSOR SYSTEM IS DISPLAYED............................................................................................................................................................................. 564 c) b0b3 [E. <-->b.3, E.C<-->b.3] ABNORMALITY IN AIR PRESSURE SENSOR SYSTEM IS DISPLAYED........................................................................................................................................................................... 565 d) b0b4 [E. <-->b.4, E.C<-->b.4] ABNORMALITY IN RETARDER BRAKE OIL TEMPERATURE SENSOR IS DISPLAYED................................................................................................................................................................ 566 A-18 WARNING DISPLAY.................................................................................................................................................................................................................................................. 567 a) b0d1 [E. <-->d.1, E.C<-->d.1] TRANSMISSION FILTER CLOGGED WARNING IS DISPLAYED................................................................................................................................................................................. 567 b) b0d5 [E. <-->d.5, E.C<-->d.5] TILT WARNING IS DISPLAYED........................................................................................................................................................................................................ 568 c) b0d6 [E. <-->d.6, E.C<-->d.6] DROP IN RADIATOR WATER LEVEL WARNING IS DISPLAYED................................................................................................................................................................................ 569 d) b0d7 [E. <-->d.7, E.C<-->d.7] BATTERY CHARGE LEVEL WARNING IS DISPLAYED........................................................................................................................................................................................ 570 e) b0E5 [E. <-->E.5, E.C<-->E.5] STEERING OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED........................................................................................................................................................................... 571 f) b0F6 [E. <-->F.6, E.C<-->F.6] REAR BRAKE OIL PRESSURE WARNING IS DISPLAYED..................................................................................................................................................................................... 572 A-19 b0C1 [E. <-->C.1, E.C<-->C.1] ABNORMALITY IN CONNECTOR CONNECTION IS DISPLAYED................................................................................................................................................................................... 573 A-20.................................................................................................................................................................................................................................................................. 574 a) b0d2 [E. <-->d.2, E.C<-->d.2] TORQUE CONVERTER OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED................................................................................................................................................................... 574 b) b0E9 [E. <-->E.9, E.C<-->E.9] AIR PRESSURE DROP WARNING IS DISPLAYED........................................................................................................................................................................................... 574 c) b0F3 [E. <-->F.3, E.C<-->F.3] RETARDER BRAKE OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED..................................................................................................................................................................... 574 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.................................................................................................................. 575 e) b0d9 [E. <-->d.9, E.C<-->d.9] ENGINE OVERSHOOT ACTUATED IS DISPLAYED........................................................................................................................................................................................... 575 f) b0dF [E. <-->d.F, E.C<-->d.F] ENGINE OVERRUN PREVENTION ACTUATED 2 IS DISPLAYED................................................................................................................................................................................ 576 TEOUBLESHOOTING OF SUSPENSION CONTROLLER SYSTEM (SP MODE)................................................................................................................................................................................................................. 577 JUDGMENT TABLE FOR SUSPENSION CONTROLLER, SUSPENSION RELAED PARTS..................................................................................................................................................................................................... 578 ACTION TAKEN BYSELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE......................................................................................................................................................................................................... 580 ELECTRICAL CIRCUIT DIAGRAM OF SUSPENSION CONTROLLER SYSTEM............................................................................................................................................................................................................ 584 SP-1 d001 [ALL OFF or E.<-->01] ABNORMALITY IN POWER SOURCE IS DISPLAYED.............................................................................................................................................................................................. 586 SP-2 d011 [E.<-->11 IS DISPLAYED] ABNORMALITY IN PRESSURE SENSOR [RIGHT] SYSTEM IS DISPLAYED.......................................................................................................................................................................... 587 SP-3 d012 [E.<-->12 IS DISPLAYED] ABNORMALITY IN PRESSURE SENSOR [LEFT] SYSTEM IS DISPLAYED........................................................................................................................................................................... 588 SP-4 d015 [E.<-->15 IS DISPLAYED] ABNORMALITY IN TRAVEL SPEED SENSOR SYSTEM IS DISPLAYED.............................................................................................................................................................................. 589 SP-5 d016 [E.<-->16 IS DISPLAYED] ABNORMALITY IN STEERING SENSOR SYSTEM IS DISPLAYED.................................................................................................................................................................................. 590 SP-6 d0C2 [E.<-->C2 IS DISPLAYED] DEFECTIVE MODEL SELECTION DATA IS DISPLAYED......................................................................................................................................................................................... 591 SP-7 d021 [E.<-->21 IS DISPLAYED] ABNORMALITY IN SOLENOID [1] SYSTEM IS DISPLAYED..................................................................................................................................................................................... 592 SP-8 d022 [E.<-->22 IS DISPLAYED] ABNORMALITY IN SOLENOID [2] SYSTEM IS DISPLAYED..................................................................................................................................................................................... 593 SP-9 d023 [E.<-->23 IS DISPLAYED] ABNORMALITY IN SOLENOID [3] SYSTEM IS DISPLAYED..................................................................................................................................................................................... 594 SP-10 d0C1 [E.<-->C1 IS DISPLAYED] DISCONNECTION IN NETWROK IS DISPLAYED.............................................................................................................................................................................................. 595 SP-11 d0C3 [E.<-->C3 IS DISPLAYED] DEFECTIVE TRAVEL SPEED COMPENSATION DATA IS DISPLAYED.............................................................................................................................................................................. 596 TROUBLESHOOTING OF PAYLOAD METER (PRINTER TYPE) SYSTEM (LP MODE).......................................................................................................................................................................................................... 597 SERVICE CODES AND SELF-DIAGNOSIS OF PAYLOAD METER (PRINTER TYPE)...................................................................................................................................................................................................... 598 ELECTRICAL CIRCUIT DIAGRAM FOR PAYLOAD METER (PRINTER TYPE) SYSTEM ................................................................................................................................................................................................... 599 LP-1 NO DISPLAY APPEARS WHEN STARTING SWITCH IS TURNED ON............................................................................................................................................................................................................. 601 LP-2 CALIBRATION DEMAND(CAL FLASHES) IS SHOWN CONTINUOUSLY AFTER STARTING SWITCH IS TUENED ON......................................................................................................................................................................... 602 LP-3 CALIBRATION CANNOT BE CARRIED OUT................................................................................................................................................................................................................................ 603 LP-4 AFTER STARTING SWITCH IS TURNED ON, ALL EXTERNAL DISPLAY LAMPS DO NIOT LIGHT UP.................................................................................................................................................................................. 606 LP-5 CONDITION DOES NOT EXIST FOR LAMPS TO LIGHT UP, BUT EXTERNAL DISPLAY LAMPS LIGHT UP ............................................................................................................................................................................. 608 LP-6 LEVEL OF LIGHTING UP OF EXTERNAL DISPLAY LAMPS IS NOT CORRECT.................................................................................................................................................................................................... 609 LP-7 ABNORMALITY IN DISPLAY LOGIC..................................................................................................................................................................................................................................... 611 LP-8 E01-E04 IS DISPLAYED............................................................................................................................................................................................................................................. 616 LP-9 E11-E14 IS DISPLAYED............................................................................................................................................................................................................................................. 617 LP-10 E21-E28 IS DISPLAYED BY SENSOR CHECK ........................................................................................................................................................................................................................... 618 LP-11 E31 IS DISPLAYED................................................................................................................................................................................................................................................ 619 LP-12 E32 IS DISPLAYED................................................................................................................................................................................................................................................ 621 LP-13 E41 IS DISPLAYED................................................................................................................................................................................................................................................ 623 LP-14 E42 IS DISPLAYED................................................................................................................................................................................................................................................ 624 LP-15 PRINTER DOES NOT PRINT ANYTHING (BLANK PAPER COMES OUT)......................................................................................................................................................................................................... 625 LP-16 PRINTER PRINTS ONLY "NO DATA"................................................................................................................................................................................................................................... 625 LP-17 PRINTER DOES NOT PRINT OUT WHEN PRT SWITCH IS PRESSED........................................................................................................................................................................................................... 625 LP-18 "PAPE"FLASHES................................................................................................................................................................................................................................................... 626 LP-19 TIME IS WRONG .................................................................................................................................................................................................................................................. 626 LP-20 E33 IS DISPLAYED................................................................................................................................................................................................................................................ 626 TROUBLESHOOTING OF PAYLOAD METER Ⅱ (CARD TYPE)SYSTEM(LC NODE)............................................................................................................................................................................................................. 627 SERVICE CODES AND SELF-DIAGNOSIS OF PAYLOAD METER Ⅱ (CARD TYPE)....................................................................................................................................................................................................... 628 ELECTRICAL CIRCUIT DIAGRAM FOR PAYLOAD METER Ⅱ (CARD TYPE) SYSTEM..................................................................................................................................................................................................... 631 LC-1 NO DISPLAY APPEARS WHEN STARTING SWITCH IS TURNED ON............................................................................................................................................................................................................. 633 LC-2 AFTER STARTING SWITCH IS TURNED ON, ALL EXTERNAL DISPLAYED LAMPS DO NOT LIGHT UP ................................................................................................................................................................................ 634 LC-3 CONDITION DOES NOT EXIST FOR LAMPS TO LIGHT UP, BUT EXTERNAL DISPLAY LAMPS LIGHT UP ............................................................................................................................................................................. 635 LC-4 LEVEL OF LIGHTING UP OF EXTERNAL DISPLAY LAMPS IS NOT CORRECT.................................................................................................................................................................................................... 636 LC-5 CYCLE DATA IS NOT RECORDED, ON/OFF DATA IS NOT RECORDED:BATTERY CHARGE SIGNAL SYSTEM: ENGINE NOT STARTED IS DETECTED............................................................................................................................................. 638 LC-6 CALIBRATION CANNOT BE CARRIED OUT, TIME DISPLAY DOES NOT MATCH CONDITIONS: SHIFT LEVER N POSITION SIGNAL SYSTEM.................................................................................................................................................. 639 LC-7 ABNORMALITY IN DISPLAY LOGIC..................................................................................................................................................................................................................................... 640 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............................................................................................................................... 642 LC-9 F-09 IS DISPLAYED: DROP IN VOLTAGE OF BACK-UP BATTERY BULIT INTO PAYLOAD METER................................................................................................................................................................................... 643 LC-10 FULL DISPLAY APPEARS............................................................................................................................................................................................................................................ 643 LC-11 F-20 IS DISPLAYED: SENSOR POWER SOURCE VOLTAGE SYSTEM........................................................................................................................................................................................................... 644 LC-12 F-21-F-24 IS DISPLAYED: DISCONNECTION, SHORT CIRCUIT WITH GROUND IN SUSPENSION PRESSURE SENSOR SYSTEM........................................................................................................................................................... 645 LC-13 F-25-F-28 IS DISPLAYED: SHORT CIRCUIT IN SUSPENSION PRESSURE SENSOR SYSTEM POWER SOURCE......................................................................................................................................................................... 647 LC-14 F. CAL IS DISPLAYED: CALIBRATION NOT CARRIED OUT, DAMAGED DATA INSIDE PAYLOAD METER............................................................................................................................................................................. 648 LC-15 F-41-F-45 IS DISPLAYED: SHORT CIRCUIT IN EXTERNAL DISPLAY LAMP SYSTEM POWER SOURCE............................................................................................................................................................................. 649 LC-16 L-BAD IS DISPLAYED : CYCLE DATA SAVED WHEN MACHINE WAS SWAYING.................................................................................................................................................................................................. 651 LC-18 F-31 IS DISPLAYED: DISCONNECTION, SHORT CIRCUIT WITH GROUND IN CLINOMETER SYSTEM................................................................................................................................................................................ 653 LC-19 F-32 IS DISPLAYED: SHORT CIRCUIT WITH CLINOMETER SYSTEM POWER SOURCE............................................................................................................................................................................................ 654 LC-20 F-18 IS DISPLAYED: DISCONNECTION IN BATTERY CHARGE SIGNAL....................................................................................................................................................................................................... 655 TROUBLESHOOTING OF ABS/ASR SYSTEM ........................................................................................................................................................................................................................................ 656 FLOWCHART OF TROUBLESHOOTING ......................................................................................................................................................................................................................................... 657 WHEN ONLY ABS IS INSTALLED........................................................................................................................................................................................................................................ 657 WHEN ABS AND ASR ARE INSTALLED.................................................................................................................................................................................................................................... 658 METHOD OF DELETING TROUBLE DATA OF ECU................................................................................................................................................................................................................................ 659 PROCEDURE FOR DELETING TEOUBLE DATA............................................................................................................................................................................................................................... 659 METHOD OF TROUBLESHOOTING USING SELF-DIAGNOSTIC FUNCTION OF ECU....................................................................................................................................................................................................... 660 INDEX (TROUBLESHOOTING CODE)...................................................................................................................................................................................................................................... 661 SYSTEM CHECK SHEET FOR SYSTEM CHECKER................................................................................................................................................................................................................................. 663 TROUBLESHOOTING....................................................................................................................................................................................................................................................... 671 W-1 WARNING LAMP DOES NOT LIGHT UP ............................................................................................................................................................................................................................... 671 I-1 ASR INFORMATION LAMP DOES NOT GO OFF.......................................................................................................................................................................................................................... 672 ASR-1 TROUBLE IN ASR CONTROL VALVE (FOR ONLY MACHINE WITH ABS AND ASR)............................................................................................................................................................................................ 673 ASR-2............................................................................................................................................................................................................................................................. 674 ABS-1 TROUBLE IN ECU.............................................................................................................................................................................................................................................. 675 ABS-2 TROUBLE IN RIGHT FRONT PRESSURE CONTROL VALVE............................................................................................................................................................................................................... 676 ABS-3 TROUBLE IN LEFT FRONT PRESSURE CONTROL VALVE ............................................................................................................................................................................................................... 677 ABS-4 TROUBLE IN LEFT REAR PRESSURE CONTROL VALVE................................................................................................................................................................................................................. 678 ABS-5 TROUBLE IN RIGHT REAR PRESSURE CONTROL VALVE................................................................................................................................................................................................................ 679 ABS-6 TROUBLE IN RIGHT FRONT WHEEL SPEED SENSOR................................................................................................................................................................................................................... 680 ABS-10 ABNORMALITY IN RIGHT FRONT WHEEL SPEED SENSOR OUTPUT....................................................................................................................................................................................................... 680 ABS-7 TROUBLE IN LEFT FRONT WHEEL SPEED SENSOR.................................................................................................................................................................................................................... 681 ABS-11 ABNORMALITY IN LEFT FRONT WHEEL SPEED SENSOR OUTPUT........................................................................................................................................................................................................ 681 ABS-8 TROUBLE IN LEFT REAR WHEEL SPEED SENSOR..................................................................................................................................................................................................................... 682 ABS-12 ABNORMALITY IN LEFT REAR WHEEL SPEED SENSOR OUTPUT......................................................................................................................................................................................................... 682 ABS-9 TROUBLE IN RIGHT REAR WHEEL SPEED SENSOR.................................................................................................................................................................................................................... 683 ABS-13 ABNORMALITY IN RIGHT REAR WHEEL SPEED SENSOR OUTPUT........................................................................................................................................................................................................ 683 ABS-14 TROUBLE IN VALVE RELAY (VR2)............................................................................................................................................................................................................................... 684 ABS-15 TROUBLE IN VALVE RELAY (VR1)............................................................................................................................................................................................................................... 685 ABS-16 TROUBLE IN VALVE RELAY (VR2)............................................................................................................................................................................................................................... 686 ABS-17 TROUBLE IN VALVE RELAY (VR1)............................................................................................................................................................................................................................... 687 ABS-18 ABNORMALITY IN SOURCE VOLTAGE.............................................................................................................................................................................................................................. 688 TROUBLESHOOTING OF ARSC [AUTOMATIC RETARDER SPEED CONTROLLER] SYSTEM (R NODE)............................................................................................................................................................................................. 689 OUTLINE............................................................................................................................................................................................................................................................... 690 ELECTRCAL CIRCUIT DIAGRAM FOR ARSC (AUTOMATIC RETADER SPEED CONTROLLER) SYSTEM........................................................................................................................................................................................ 693 R-1 0.1 (ABNORMALITY IN POWER SOURCE VOLTAGE) IS DISPLAYED............................................................................................................................................................................................................ 695 R-2 1.0 (DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED.................................................................................................................................................................................................... 696 R-3 1.3 (DISCONNECTION IN TRANSMISSION OUTPUT SHAFT SPEED SENSOR SYSTEM) IS DISPLAYED................................................................................................................................................................................. 697 R-4 1.5 (FAILURE IN RETARDER OIL TEMPERATURE SENSOR SYSTEM) IS DISPLAYED.............................................................................................................................................................................................. 698 R-5 1.7 (FAILURE IN ACCELERATOR SIGNAL SYSTEM) IS DISPLAYED........................................................................................................................................................................................................... 699 R-6 1.8 (FAILURE IN SUSPENSION PRESSURE SENSOR "LEFT" SYSTEM) IS DISPLAYED............................................................................................................................................................................................ 700 R-7 1.9 (FAILURE IN SUSPENSION PRESSURE SENSOR "RIGHT" SYSTEM) IS DISPLAYED........................................................................................................................................................................................... 701 R-8 4.2 (DISCONNECTION IN EXHAUST BRAKE SELECTOR SIGNAL SYSTEM) IS DISPLAYED.......................................................................................................................................................................................... 702 R-9 4.3 (DISCONNECTION IN ARSC CAUTION LAMP SYSTEM) IS DISPLAYED...................................................................................................................................................................................................... 703 R-10 4.4 (DISCONNECTION IN READY LAMP SYSTEM) IS DISPLAYED............................................................................................................................................................................................................ 704 R-11 4.5 (DISCONNECTOIN IN PANEL CAUTION AND BUZZER SYSTEM) IS DISPLAYED.............................................................................................................................................................................................. 705 R-12 5.2 (SHORT CIRCUIT WITH GROUND IN EXHAUST BRAKE SELECTOR SIGNAL OUTPUT SYSTEM) IS DISPLAYED...................................................................................................................................................................... 706 R-13 5.3 (SHORT CIRCUIT WITH GROUND IN ARSC CAUTION LAMP SYSTEM) IS DISPLAYED......................................................................................................................................................................................... 707 R-14 5.4 (SHORT CIRCUIT WITH GROUND IN READY OUTPUT CIRCUIT SYSTEM) IS DISPLAYED...................................................................................................................................................................................... 708 R-15 5.5 (SHORT CIRCUIT WITH GROUND IN PANEL CAUTION LAMP AND BUZZER OUTPUT SYSTEM) IS DISPLAYED...................................................................................................................................................................... 709 R-16 6.0 (FAILURE IN ENGINE SPEED SYSTEM) IS DISPLAYED................................................................................................................................................................................................................ 710 R-17 7.0 (DISCONNECTION IN TRAVEL SPEED DISPLAY UP OUTPUT SYSTEM) IS DISPLAYED........................................................................................................................................................................................ 711 R-18 7.1 (DISCONNECTION IN TRAVEL SPEED DISPLAY DOWN OUTPUT SYSTEM) IS DISPLAYED...................................................................................................................................................................................... 712 R-19 7.2 (DISCONNECTION IN TRAVEL SPEED DISPLAY CLEAR OUTPUT SYSTEM) IS DISPLAYED..................................................................................................................................................................................... 713 R-20 7.3 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY UP OUTPUT SYSTEM) IS DISPLAYED ........................................................................................................................................................................... 714 R-21 7.4 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY DOWN OUTPUT SYSTEM) IS DISPLAYED.......................................................................................................................................................................... 715 R-22 7.5 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY CLEAR OUTPUT SYSTEM)IS DISPLAYED.......................................................................................................................................................................... 716 R-23 8.1 (SHORT CIRCUIT WITH GROUND IN PRESSURE CONTROL VALVE SYSTEM) IS DISPLAYED.................................................................................................................................................................................... 717 R-24 8.3 (DISCONNECTION IN PRESSURE CONTROL VALVE SYSTEM) IS DISPLAYED................................................................................................................................................................................................ 718 R-25 8.5 (FAILURE IN PRESSURE CONTEOL VALVE [PRESSURE CONTROL VALVE REMAINS OPEN) IS DISPLAYED........................................................................................................................................................................ 719 R-26 8.7 (FAILURE IN PRESSURE CONTROL VALVE(PRESSURE CONTROL VALVE DOES NOT OPEN) IS DISPLAYED........................................................................................................................................................................ 720 R-27 8.9 (SHORT CIRCUIT WITH GROUND IN PRESSURE SWITCH VALVE SYSTEM) IS DISPLAYED..................................................................................................................................................................................... 721 R-28 9.0 (DISCONNECTION IN PRESSURE SWITCH VALVE SYSTEM) IS DISPLAYED................................................................................................................................................................................................. 722 R-29 9.1 (FAILURE IN PRESSURE SWITCH VALVE SYSTEM (REMAINS OPEN)) IS DISPLAYED........................................................................................................................................................................................ 723 R-30 9.2 (FAILURE IN PRESSURE SWITCH VALVE SYSTEM (DOES NOT OPEN)) IS DISPLAYED....................................................................................................................................................................................... 724 R-31 9.3 (DISCONNECTION IN SYSTEM SWITCH SYSTEM) IS DISPLAYED......................................................................................................................................................................................................... 725 R-32 9.4 (SHORT CIRCUIT WITH GROUND IN SYSTEM SWITCH SYSTEM) IS DISPLAYED............................................................................................................................................................................................. 726 R-33 9.5 (DISCONNECTION, SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED SETTING SWITCH SYSTEM) IS DISPLAYED................................................................................................................................................................ 727 R-101 SET SPEED CANNOT BE SET......................................................................................................................................................................................................................................... 728 R-102 FAILURE CODE IS ALWAYS CLEARED (CONTROLLER DISPLAY WINDOW ALWAYS SHOWS "--") OR FAILURE CODE CANNOT BE CLEARED.................................................................................................................................................. 731 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).................................................................................................................. 732 R-105 WHEN TRAVELING DOWNHILL, EVEN WHEN SET SPEED IS EXCEEDED, NO CONTROL IS CARRLED OUT............................................................................................................................................................................. 733 R-106 MONITOR LAMP (BUZZER) STAYS ON (OR OFF)......................................................................................................................................................................................................................... 734 R-107 READY LAMP DOES NOT LIGHT UP (OR STAYS LIGHTED UP).............................................................................................................................................................................................................. 735 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)............................................................................................. 737 R-109 THERE IS DIFFERENCE BETWEEN TRAVEL SPEED ROD VALUE AND ACTUAL MACHINE VALUE..................................................................................................................................................................................... 739 R-110 RETARDER LAMP DOES NOT LIGHT UP, OR STAYS LIGHTED UP............................................................................................................................................................................................................ 741 R-111 TRAVEL SPEED DISPLAY ALWAYS GIVES DISPLAY (OR DOES NOT GIVE ANY DISPLAY)........................................................................................................................................................................................ 742 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H MODE).............................................................................................................................................................................................................. 743 H-1 MACHINE DOES NOT START............................................................................................................................................................................................................................................ 744 H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE JERKS).................................................................................................................................................................................................................. 746 H-3 LOCK-UP CLUTCH CANNOT BE DISENGAGED (ENGINE STALLS)............................................................................................................................................................................................................... 746 H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING......................................................................................................................................................................................................................... 747 H-5 TRANSMISSION DOES NOT SHIFT UP ................................................................................................................................................................................................................................... 747 H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING....................................................................................................................................................................................................................... 748 H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR.............................................................................................................................................................................................................. 752 H-8 TORQUE CONVERTAR OIL TEMPERATURE IS HIGH.......................................................................................................................................................................................................................... 754 H-9 TORQUE CONVERTER OIL PRESSURE IS LOW.............................................................................................................................................................................................................................. 755 H-10 FRONT BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE........................................................................................................................................................................................................ 756 H-11 REAR BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE......................................................................................................................................................................................................... 757 H-12 STEERING WHEEL IS HEAVY.......................................................................................................................................................................................................................................... 758 H-13 STEERING WHEEL DOES NOT WORK..................................................................................................................................................................................................................................... 759 H-14 STEERING WHEEL VIBRATES.......................................................................................................................................................................................................................................... 759 H-15 HOIST CYLINDER LACKS LIFTING FORCE (LIFTING SPEED)............................................................................................................................................................................................................... 760 H-16 HOIST CYLINDER DOES NOT WORK..................................................................................................................................................................................................................................... 761 H-17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY........................................................................................................................................................................................................................... 762 H-18 AIR PRESSURE DOES NOT RISE (LOW-PRESSURE BUZZER DOES NOT STOP, AIR GAUGE DOES NOT RISE TO GREEN RANGE)........................................................................................................................................................... 763 TROUBLESHOOTING OF MONITOR PANEL SYSTEM (P MODE).......................................................................................................................................................................................................................... 764 METHOD OF SELF-DIAGNOSTIC DISPLAY FOR MONITOR PANEL AND CONTROLLERS................................................................................................................................................................................................... 766 ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE........................................................................................................................................................................................................ 767 ELECTRICAL CIRCUIT DIAGRAM FOR MONITOR PANEL SYSTEM................................................................................................................................................................................................................... 771 P-1 CHECK PATTERN FOR WIRING HARNESSES BETWEEN MODULES................................................................................................................................................................................................................ 773 P-2 NOTHING ON MONITOR PANAL WORKS.................................................................................................................................................................................................................................... 777 P-3 LH, RH MODULE AND FUEL GAUGE DO NOT WORK.......................................................................................................................................................................................................................... 778 P-4 LH, RH MODULE AND FUEL GAUGE DO NOT WORK.......................................................................................................................................................................................................................... 779 P-5 RH MODULE DOES NOT WORK .......................................................................................................................................................................................................................................... 780 P-6 LH MODULE DOES NOT WORK........................................................................................................................................................................................................................................... 781 P-7 TRAVEL CALCULATOR DOES NOT WORK................................................................................................................................................................................................................................... 782 P-8 SERVICE METER DISPLAY DOES NOT WORK CORRECTLY..................................................................................................................................................................................................................... 783 P-9 CENTRAL WARNING LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS FAILURE CODE (MONITOR PANEL DISPLAY) [A002].......................................................................................................................................................... 784 P-10 CENTRAL WARNING LAMP STAYS LIGHTED UP............................................................................................................................................................................................................................ 785 P-11 ALARM BUZZER DOES NOT WORK, OR MONITOR PANEL DETECTS FAILURE CODE [A003]......................................................................................................................................................................................... 786 P-12 ALARM BUZZER CONTINUES TO SOUND.................................................................................................................................................................................................................................. 787 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]....................... 788 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]........................................................................................................ 789 P-15 GAUGE DISPLAYS ARE ABNORMAL (NOTHING IS DISPLAYED, OR DISPLY DOES NOT CHANGE).................................................................................................................................................................................... 790 P-16 COOLING WATER LEVEL DROP CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]................................................................................................................................................................ 791 P-17 COOLING WATER LEVAL DROP CAUTION LAMP STAYS LIGHTED UP........................................................................................................................................................................................................... 792 P-18 EMERGENCY STEERING PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]........................................................................................................................................................................ 793 P-19 EMERGENCY STEERING PILOT LAMP STAYS LIGHTED UP .................................................................................................................................................................................................................. 794 P-20 ENGINE OIL PRESSURE DROP CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]................................................................................................................................................................ 795 P-21 ENGINE OIL PRESSURE DROP CAUTION LAMP STAYS LIGHTED UP........................................................................................................................................................................................................... 796 P-22 EXHAUST BRAKE PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]............................................................................................................................................................................. 797 P-23 EXHAUST BRAKE PILOT LAMP STAYS LIGHTED UP........................................................................................................................................................................................................................ 798 P-24 CHARGING CIRCUIT ABNORMALITY CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]............................................................................................................................................................ 799 P-25 CHARGING CIRCUIT ABNORMALITY CAUTION LAMP STAYS LIGHTED UP....................................................................................................................................................................................................... 800 P-26 TRANSMISSION FILTER CLOGGING CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]............................................................................................................................................................ 801 P-27 TRANSMISSION FILTER CLOGGING CAUTION LAMP STAYS LIGHTED UP....................................................................................................................................................................................................... 802 P-28 BRAKE STROKE CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]............................................................................................................................................................................ 803 P-29 BRAKE STROKE CAUTION LAMP STAYS LIGHTED UP....................................................................................................................................................................................................................... 804 P-30 PREHEATING SWITCH PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]......................................................................................................................................................................... 805 P-31 PREHEATING SWITCH PILOT LAMP STAYS LIGHTED UP.................................................................................................................................................................................................................... 806 P-32 TILT WARNING LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001].................................................................................................................................................................................... 807 P-33 TILT WARNING LAMP STAYS LIGHTED UP............................................................................................................................................................................................................................... 808 P-34 BODY FLOAT (EXCEPT FLOAT) PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]................................................................................................................................................................. 809 P-35 BODY FLOAT (EXCEPT FLOAT) PILOT LAMP STAYS LIGHTED UP............................................................................................................................................................................................................ 810 P-36 REAR BRAKE PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]................................................................................................................................................................................ 811 P-37 REAR BRAKE PILOT LAMP STAYS LIGHTED UP........................................................................................................................................................................................................................... 812 P-38 PARKING BRAKE PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]............................................................................................................................................................................. 813 P-39 PARKING BRAKE PILOT LAMP STAYS LIGHTED UP........................................................................................................................................................................................................................ 814 P-40 MAINTENANCE CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]............................................................................................................................................................................. 815 P-41 MAINTENANCE CAUTION LAMP STAYS LIGHTED UP........................................................................................................................................................................................................................ 816 P-42 STEERING OIL TEMPERATURE CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]................................................................................................................................................................ 817 P-43 STEERING OIL TEMPERATURE CAUTION LAMP STAYS LIGHTED UP........................................................................................................................................................................................................... 818 P-44 DIFFERENTIAL LOCK PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]......................................................................................................................................................................... 819 P-45 DIFFERENTIAL LOCK PILOT LAMP STAYS LIGHTED UP.................................................................................................................................................................................................................... 820 P-46 HIGH BEAM DISPLAY DOES NOT LIGHT UP.............................................................................................................................................................................................................................. 821 P-47 TURN SIGNAL LAMP (RIGHT) DOES NOT LIGHT UP....................................................................................................................................................................................................................... 823 P-48 TURN SIGNAL LAMP (LEFT) DOES NOT LIGHT UP........................................................................................................................................................................................................................ 824 P-49 LAMP CHECK SWITCH DOES NOT WORK.................................................................................................................................................................................................................................. 825 P-50 AISS SWITCH DOES NOT WORK........................................................................................................................................................................................................................................ 826 P-51 EXHAUST BRAKE SWITCH DOES NOT WORK............................................................................................................................................................................................................................... 827 P-52 MODE CHANGE SWITCH (1) DOES NOT WORK............................................................................................................................................................................................................................. 828 P-53 MODE CHANGE SWITCH (2) DOES NOT WORK............................................................................................................................................................................................................................. 829 P-54 KPH/MPH SPEEDOMETER UNIT SELECTOR DOES NOT WORK.................................................................................................................................................................................................................. 830 P-55 DEFECTIVE OPERATION OF ALL SWITCH INPUTS......................................................................................................................................................................................................................... 831 P-56 MONITOR PANEL DETECTS SERVICE CODES [A014] OR [A019]............................................................................................................................................................................................................. 832 P-57 MONITOR PANEL DETECTS SERVICE CODE [A015]........................................................................................................................................................................................................................ 833 P-58 MONITOR PANEL DETECTS SERVICE CODE [A011]........................................................................................................................................................................................................................ 834 P-59 MONITOR PANEL DETECTS SERVICE CODE [A012]........................................................................................................................................................................................................................ 834 P-60 MONITOR PANEL DETECTS SERVICE CODE [A000]........................................................................................................................................................................................................................ 834 VHMS MACHINE HEALTH DIAGNOSIS SYSTEM (OPT)................................................................................................................................................................................................................................ 835 1. BASIC PRECAUTIONS.................................................................................................................................................................................................................................................. 836 1-1. OPERAION, SAFETY, INSPECITON AND MAINTENANCE OF MACHINE ..................................................................................................................................................................................................... 836 1-2. OPERATION OF MONITORING SYSTEM............................................................................................................................................................................................................................... 836 1-3. CONSTANT POWER SUPPLY (BATERY DIRECT POWER SUPPLY)........................................................................................................................................................................................................... 836 1-4. PRECAUTIONS AT THE TIME OF TURNING ON THE POWER FOR VHMS..................................................................................................................................................................................................... 837 1-5. PRECAUTIONS AT THE TIME OF REPLACING VHMS AND TRANSMISSION CONTROLLER........................................................................................................................................................................................ 837 1-6. OPERATION OF COMMUNICATION (ORB...ORB COMMUNICATION) CONTROLLER.............................................................................................................................................................................................. 838 2. OVERVIEW........................................................................................................................................................................................................................................................... 839 2-1. APPLICABLE MODEL............................................................................................................................................................................................................................................. 839 2-2. BASIC CONFIGURATION.......................................................................................................................................................................................................................................... 839 2-3. INSTALLATION DRAWING......................................................................................................................................................................................................................................... 842 3. STRUCTURE AND FUNCTION............................................................................................................................................................................................................................................. 844 3-1. VHMS CONTROLLER.............................................................................................................................................................................................................................................. 844 3-2. BLOW-BY GAS SENSOR........................................................................................................................................................................................................................................... 844 3-3. ENGINE OIL TEMPERAUTRE SENSOR................................................................................................................................................................................................................................ 845 3-4. AMPLIFIER FOR EXHAUST GAS TEMPERATURE SENSOR................................................................................................................................................................................................................. 846 3-5. COMMUNICATION (ORB...ORB COMMUNICATION) CONTROLLER/ANTENNA................................................................................................................................................................................................... 847 4. TROUBLESHOOTING.................................................................................................................................................................................................................................................... 848 4-1. TROUBLESHOOTING EQUIPMENT LIST............................................................................................................................................................................................................................... 848 4-2. CONNECTOR TYPES AND MOUNTING LOCATIONS....................................................................................................................................................................................................................... 849 4-3. CONNECTOR ARRANGEMENT DIAGRAM................................................................................................................................................................................................................................ 850 4-4. VHMS RELATED ELECTRICAL CIRCUIT DIAGRAM...................................................................................................................................................................................................................... 855 4-5. ERROR CODE LIST.............................................................................................................................................................................................................................................. 857 4-6. STANDARD VALUE TABLE FOR ELECTRICAL PARTS.................................................................................................................................................................................................................... 858 4-7. TROUBLE PHENOMENA LIST....................................................................................................................................................................................................................................... 859 HM-1: ABNORMALITY IN SATELLITE DATA TRANSMISSION.................................................................................................................................................................................................................. 861 HM-2: ABNORMALITY IN DOWNLOADING OR SETTING WITH THE PC........................................................................................................................................................................................................... 862 HM-3: MANUAL SNAP HAS NOT BEEN RECORDED........................................................................................................................................................................................................................... 863 HM-4: ABNORMAL BLOW-BY GAS PRESSURE............................................................................................................................................................................................................................... 864 HM-5: ABNORMAL EXHAUST GAS TEMPERATURE............................................................................................................................................................................................................................ 865 HM-6: ABNORMAL ENGINE OIL TEMPERATURE............................................................................................................................................................................................................................. 866 HM-7: ABNORMAL ENGINE OIL PRESSURE................................................................................................................................................................................................................................ 867 HM-8: ABNORMAL ENGINE SPEED....................................................................................................................................................................................................................................... 868 HM-9: ABNORMAL FUEL INJECTION AMOUNT.............................................................................................................................................................................................................................. 869 HM-10: T/M DATE IS NOT DISPLAYED.................................................................................................................................................................................................................................. 870 HM-11: WHILE TRAVELLING, TRAVEL VALVE SUDDENLY BECOMES NEUTRAL AND CANNOT TRAVEL.................................................................................................................................................................................. 870 5. SETTING OF VHMS CONTROLLER......................................................................................................................................................................................................................................... 871 5-1. SETTING OF VHMS CONTROLLER................................................................................................................................................................................................................................... 871 5-2. SETTING ITEM................................................................................................................................................................................................................................................. 871 5-3. SETTING FLOW (OUTLINE)....................................................................................................................................................................................................................................... 871 5-4. CHECK OF OPERATION AND PERFORMANCE........................................................................................................................................................................................................................... 872 5-5. DATA COLLECTION.............................................................................................................................................................................................................................................. 872 6. DATA RECOVERY AND TRANSMISSION..................................................................................................................................................................................................................................... 873 6-1. DATA RECOVERY................................................................................................................................................................................................................................................ 873 7. INSPECTION AND MAINTENANCE......................................................................................................................................................................................................................................... 880 7-1. INSPECTION TIMING: INSPECTION AND MAINTENANCE TIMING OF MACHINE.............................................................................................................................................................................................. 880 7-2. INSPECTION ITEM.............................................................................................................................................................................................................................................. 880 7-3. CORRECTIVE ACTION............................................................................................................................................................................................................................................ 880 8. REPLACEMENT OF PARTS............................................................................................................................................................................................................................................... 880 8-1. IF INITIAL SET-UP OF VHMS SYSTEM HAS BEEN MADE OR VHMS CONTROLLER HAS BEEN REPLACED.......................................................................................................................................................................... 880 8-2. WHEN COMMUNICATION CONTROLLER IS REPLACED.................................................................................................................................................................................................................... 880 PROCEDURE Ⅰ FOR INITIAL SETUP OF VHMS................................................................................................................................................................................................................................. 881 PROCEDURE Ⅱ FOR OPENING ORBCOMM SERVICE............................................................................................................................................................................................................................... 883 30 DISASSEMBLY AND ASSEMBLY....................................................................................................................................................................................................................................................... 887 METHOD OF USING MANUAL........................................................................................................................................................................................................................................................ 889 PRECAUTIONS WHEN CARRYING OUT OPERATION....................................................................................................................................................................................................................................... 890 SPECIAL TOOL LIST............................................................................................................................................................................................................................................................. 892 STARTING MOTOR................................................................................................................................................................................................................................................................ 895 REMOVAL AND INSTALLATION.................................................................................................................................................................................................................................................. 895 ALTERNATOR.................................................................................................................................................................................................................................................................... 896 REMOVAL AND INSTALLATION.................................................................................................................................................................................................................................................. 896 ENGINE OIL COOLER............................................................................................................................................................................................................................................................. 897 REMOVAL AND INSTALLATION.................................................................................................................................................................................................................................................. 897 AIR CONDITIONER COMPERSSOR.................................................................................................................................................................................................................................................... 898 REMOVAL AND INSTALLATION.................................................................................................................................................................................................................................................. 898 FUEL INJECTION PUMP........................................................................................................................................................................................................................................................... 899 REMOVAL................................................................................................................................................................................................................................................................... 899 INSTALLATION.............................................................................................................................................................................................................................................................. 900 AIR COMPRESSOR................................................................................................................................................................................................................................................................ 901 REMOVAL AND INSTALLATION.................................................................................................................................................................................................................................................. 901 AIR CONDITIONER COMPERSSOR.................................................................................................................................................................................................................................................... 902 REMOVAL AND INSTALLATION.................................................................................................................................................................................................................................................. 902 WATER PUMP.................................................................................................................................................................................................................................................................... 903 REMOVAL AND INSTALLATION.................................................................................................................................................................................................................................................. 903 AFTERCOOLER CORE.............................................................................................................................................................................................................................................................. 904 REMOVAL AND INSTALLATION.................................................................................................................................................................................................................................................. 904 EXHAUST BRAKE CYLINDER........................................................................................................................................................................................................................................................ 905 REMOVAL AND INSTALLATION.................................................................................................................................................................................................................................................. 905 TURBOCHARGER.................................................................................................................................................................................................................................................................. 906 REMOVAL AND INSTALLATION.................................................................................................................................................................................................................................................. 906 NOZZLE HOLDER................................................................................................................................................................................................................................................................. 907 REMOVAL AND INSTALLATION.................................................................................................................................................................................................................................................. 907 CYLINDER HEAD................................................................................................................................................................................................................................................................. 908 REMOVAL................................................................................................................................................................................................................................................................... 908 INSTALLATION.............................................................................................................................................................................................................................................................. 911 ENGINE........................................................................................................................................................................................................................................................................ 912 REMOVAL................................................................................................................................................................................................................................................................... 912 INSTALLATION.............................................................................................................................................................................................................................................................. 915 ENGINE FRONT SEAL............................................................................................................................................................................................................................................................. 916 REMOVAL AND INSTALLATION.................................................................................................................................................................................................................................................. 916 ENGINE REAR SEAL.............................................................................................................................................................................................................................................................. 918 REMOVAL AND INSTALLATION.................................................................................................................................................................................................................................................. 918 RADIATOR, TORQUE CONVERTER COOLER............................................................................................................................................................................................................................................. 920 REMOVAL................................................................................................................................................................................................................................................................... 920 INSTALLTION............................................................................................................................................................................................................................................................... 922 BRAKE OIL COOLER.............................................................................................................................................................................................................................................................. 923 REMOVAL AND INSTALLATION.................................................................................................................................................................................................................................................. 923 OUTPUT SHAFT.................................................................................................................................................................................................................................................................. 924 REMOVAL AND INSTALLATION.................................................................................................................................................................................................................................................. 924 DISASSEMBLY............................................................................................................................................................................................................................................................... 926 ASSEMBLY.................................................................................................................................................................................................................................................................. 927 TORQUE CONVERTER, TRANSMISSION................................................................................................................................................................................................................................................ 929 REMOVAL................................................................................................................................................................................................................................................................... 929 INSTALLATION.............................................................................................................................................................................................................................................................. 930 PROCEDURE FOR CENTERING THE ENGINE ASSEMBLY AND TROQUE CONVERTER, TRANSMISSION ASSEMBLY....................................................................................................................................................................................... 931 TORQUE CONVERTER, CONTROL VALVE............................................................................................................................................................................................................................................... 932 REMOVAL AND INSTALLATION.................................................................................................................................................................................................................................................. 932 DISASSEMBLY AND ASSEMBLY.................................................................................................................................................................................................................................................. 933 TORQUE CONVERTER AND TRANSMISSION............................................................................................................................................................................................................................................. 934 DISCONNECTION............................................................................................................................................................................................................................................................. 934 CONNECTION................................................................................................................................................................................................................................................................ 935 TORQUE CONVERTER, PTO......................................................................................................................................................................................................................................................... 936 DISASSEMBLY............................................................................................................................................................................................................................................................... 936 ASSEMBLY.................................................................................................................................................................................................................................................................. 942 TRANSMISSION.................................................................................................................................................................................................................................................................. 949 DISASSEMBLY............................................................................................................................................................................................................................................................... 949 ASSEMBLY.................................................................................................................................................................................................................................................................. 965 TRANSMISSION CONTROL VALVE (ECMV ASSEMBLY).................................................................................................................................................................................................................................... 982 REMOVAL AND INSTALLATION.................................................................................................................................................................................................................................................. 982 ECMV.......................................................................................................................................................................................................................................................................... 983 DISASSEMBLY AND ASSEMBLY.................................................................................................................................................................................................................................................. 983 DIFFERENTIAL ................................................................................................................................................................................................................................................................. 985 REMOVAL AND INSTALLATION.................................................................................................................................................................................................................................................. 985 DISASSEMBLY............................................................................................................................................................................................................................................................... 986 ASSEMBLY.................................................................................................................................................................................................................................................................. 990 FRONT WHEEL................................................................................................................................................................................................................................................................... 999 REMOVAL AND INSTALLATION.................................................................................................................................................................................................................................................. 999 REAR WHEEL....................................................................................................................................................................................................................................................................1000 REMOVAL ..................................................................................................................................................................................................................................................................1000 INSTALLATION..............................................................................................................................................................................................................................................................1001 FRONT BRAKE CALIPER PAD.......................................................................................................................................................................................................................................................1002 REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1002 FRONT BRAKE CALIPER...........................................................................................................................................................................................................................................................1003 REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1003 DISASSEMBLY...............................................................................................................................................................................................................................................................1004 ASSEMBLY..................................................................................................................................................................................................................................................................1005 FRONT WHEEL HUB...............................................................................................................................................................................................................................................................1007 DISASSEMBLY...............................................................................................................................................................................................................................................................1007 ASSEMBLY..................................................................................................................................................................................................................................................................1009 FINAL DRIVE CARRIER...........................................................................................................................................................................................................................................................1012 REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1012 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................................................................................................1013 FIANL DRIVE...................................................................................................................................................................................................................................................................1014 DISASSEMBLY...............................................................................................................................................................................................................................................................1014 ASSEMBLY..................................................................................................................................................................................................................................................................1016 REAR BRAKE....................................................................................................................................................................................................................................................................1018 REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1018 DISASSEMBLY...............................................................................................................................................................................................................................................................1019 ASSEMBLY..................................................................................................................................................................................................................................................................1020 PARKING BRAKE PAD.............................................................................................................................................................................................................................................................1022 REMOVAL...................................................................................................................................................................................................................................................................1022 INSTALLATION..............................................................................................................................................................................................................................................................1023 PARKING BRAKE CALIPER.........................................................................................................................................................................................................................................................1025 REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1025 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................................................................................................1026 FRONT SUSPENSION CYLINDER.....................................................................................................................................................................................................................................................1027 REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1027 DISASSEMBLY...............................................................................................................................................................................................................................................................1029 ASSEMBLY..................................................................................................................................................................................................................................................................1030 VARIABLE DAMPING SELECTOR VALVE...............................................................................................................................................................................................................................................1031 DISASSEMBLY...............................................................................................................................................................................................................................................................1031 ASSEMBLY..................................................................................................................................................................................................................................................................1032 REAR SUSPENSION CYLINDER......................................................................................................................................................................................................................................................1033 REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1033 DISASSEMBLY...............................................................................................................................................................................................................................................................1034 ASSEMBLY..................................................................................................................................................................................................................................................................1035 AIR GOVERNOR..................................................................................................................................................................................................................................................................1036 REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1036 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................................................................................................1037 BRAKE VALVE...................................................................................................................................................................................................................................................................1038 REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1038 DISASSEMBLY...............................................................................................................................................................................................................................................................1039 ASSEMBLY..................................................................................................................................................................................................................................................................1041 PARKING BRAKE CHAMBER.........................................................................................................................................................................................................................................................1043 REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1043 DISASSEMBLY...............................................................................................................................................................................................................................................................1044 ASSEMBLY..................................................................................................................................................................................................................................................................1045 FRONT BRAKE CHAMBER...........................................................................................................................................................................................................................................................1047 REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1047 DISASSEMBLY...............................................................................................................................................................................................................................................................1048 ASSEMBLY..................................................................................................................................................................................................................................................................1050 REAR BRAKE CHAMBER............................................................................................................................................................................................................................................................1047 REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1047 DISASSEMBLY...............................................................................................................................................................................................................................................................1052 ASSEMBLY..................................................................................................................................................................................................................................................................1055 SLACK ADJUSTER................................................................................................................................................................................................................................................................1058 REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1058 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................................................................................................1059 AIR DRIER (DESICCANT TYPE)...................................................................................................................................................................................................................................................1060 REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1060 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................................................................................................1061 TRANSMISSION LUBRICATION, RETARDER BRAKE PUMP ................................................................................................................................................................................................................................1078 REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1078 BRAKE COOLING PUMP............................................................................................................................................................................................................................................................1079 REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1079 HOIST, STEERING PUMP..........................................................................................................................................................................................................................................................1079 REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1079 EMERGENCY STEERING MOTOR PUMP.................................................................................................................................................................................................................................................1080 REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1080 BRAKE CONTROL VALVE...........................................................................................................................................................................................................................................................1081 REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1081 STEERING VALVE................................................................................................................................................................................................................................................................1082 REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1082 DISASSEMBLY...............................................................................................................................................................................................................................................................1083 ASSEMBLY..................................................................................................................................................................................................................................................................1087 DEMAND VALVE..................................................................................................................................................................................................................................................................1094 REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1094 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................................................................................................1095 RELIEF VALVE..................................................................................................................................................................................................................................................................1096 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................................................................................................1096 HOIST VALVE...................................................................................................................................................................................................................................................................1097 REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1097 DISASSEMBLY...............................................................................................................................................................................................................................................................1098 ASSEMBLY..................................................................................................................................................................................................................................................................1099 STEERING CYLINDER.............................................................................................................................................................................................................................................................1100 REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1100 DISASSEMBLY...............................................................................................................................................................................................................................................................1101 ASSEMBLY..................................................................................................................................................................................................................................................................1103 HOIST CYLINDER................................................................................................................................................................................................................................................................1105 REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1105 DISASSEMBLY...............................................................................................................................................................................................................................................................1106 ASSEMBLY..................................................................................................................................................................................................................................................................1107 BODY..........................................................................................................................................................................................................................................................................1108 REMOVAL...................................................................................................................................................................................................................................................................1108 INSTALLATION..............................................................................................................................................................................................................................................................1109 TRANSMISSION CONTROLLER.......................................................................................................................................................................................................................................................1110 REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1110 SUSPENSION CONTROLLER.........................................................................................................................................................................................................................................................1110 REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1110 40 MAINTENANCE STANDARD...........................................................................................................................................................................................................................................................1111 OUTPUT SHAFT..................................................................................................................................................................................................................................................................1112 TURQUE CONVERTER VALVE........................................................................................................................................................................................................................................................1113 TORQUE CONVERTER..............................................................................................................................................................................................................................................................1114 TRANSMISSION..................................................................................................................................................................................................................................................................1116 ECMV..........................................................................................................................................................................................................................................................................1120 FRONT AXLE....................................................................................................................................................................................................................................................................1121 REAR AXLE SUPPORT.............................................................................................................................................................................................................................................................1122 DIFFERENTIAL..................................................................................................................................................................................................................................................................1123 FINAL DRIVE...................................................................................................................................................................................................................................................................1124 FRONT BRAKE...................................................................................................................................................................................................................................................................1125 REAR BRAKE....................................................................................................................................................................................................................................................................1126 PARKING BRAKE.................................................................................................................................................................................................................................................................1127 STEERING LINKAGE..............................................................................................................................................................................................................................................................1128 FRONT SUSPENSION CYLINDER.....................................................................................................................................................................................................................................................1130 REAR SUSPENSION CYLINDER......................................................................................................................................................................................................................................................1131 PARKING BRAKE CHAMBER.........................................................................................................................................................................................................................................................1132 SLACK ADJUSTER................................................................................................................................................................................................................................................................1133 HYDRAULIC PUMP ...............................................................................................................................................................................................................................................................1134 DEMAND VALVE..................................................................................................................................................................................................................................................................1137 CROSS-OVER RELIEF VALVE.......................................................................................................................................................................................................................................................1137 HOIST VALVE...................................................................................................................................................................................................................................................................1138 STEERING CYLINDER.............................................................................................................................................................................................................................................................1139 HOIST CYLINDER................................................................................................................................................................................................................................................................1140 90 OTHERS.........................................................................................................................................................................................................................................................................1141 ELECTRICAL CIRCUIT DIAGRAM ...................................................................................................................................................................................................................................................1142 ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (1/3)...........................................................................................................................................................................................................................1142 ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (2/3)...........................................................................................................................................................................................................................1143 ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (3/3)...........................................................................................................................................................................................................................1144 ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (1/2)..........................................................................................................................................................................................................................1145 ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (2/2)..........................................................................................................................................................................................................................1146 ELECTRICAL CONTROL SYSTEM.....................................................................................................................................................................................................................................................1147 ELECTRICAL CIRCUIT DIAGRAM................................................................................................................................................................................................................................................1147 AUTOMATIC RETARD SPEED CONTROL SYSTEM.........................................................................................................................................................................................................................................1148 ELECTRICAL CIRCUIT DIAGRAM................................................................................................................................................................................................................................................1148 AUTOMATIC SHIFT CONTROL SYSTEM................................................................................................................................................................................................................................................1149 ELECTRICAL CIRCUIT DIAGRAM................................................................................................................................................................................................................................................1149 AUTOMATIC SUSPENSION SYSTEM...................................................................................................................................................................................................................................................1150 SYSTEM CIRCUIT DIAGRAM (1/2)..............................................................................................................................................................................................................................................1150 SYSTEM CIRCUIT DIAGRAM (2/2)..............................................................................................................................................................................................................................................1151 PAYLOAD METER (PRINTER TYPE)..................................................................................................................................................................................................................................................1152 ELECTRICAL CIRCUIT DIAGRAM................................................................................................................................................................................................................................................1152 PAYLOAD METER Ⅱ (CARD TYPE)...................................................................................................................................................................................................................................................1153 ELECTRICAL CIRCUIT DIAGRAM................................................................................................................................................................................................................................................1153 ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM.................................................................................................................................................................................................................1154 VHMS MACHINE HEALTH DIAGNOSIS SYSTEM (OPT)....................................................................................................................................................................................................................................1155 1. BASIC PRECAUTIONS......................................................................................................................................................................................................................................................1156 1-1. OPERAION, SAFETY, INSPECITON AND MAINTENANCE OF MACHINE .........................................................................................................................................................................................................1156 1-2. OPERATION OF MONITORING SYSTEM...................................................................................................................................................................................................................................1156 1-3. CONSTANT POWER SUPPLY (BATERY DIRECT POWER SUPPLY)...............................................................................................................................................................................................................1156 1-4. PRECAUTIONS AT THE TIME OF TURNING ON THE POWER FOR VHMS.........................................................................................................................................................................................................1157 1-5. PRECAUTIONS AT THE TIME OF REPLACING VHMS AND TRANSMISSION CONTROLLER............................................................................................................................................................................................1157 1-6. OPERATION OF COMMUNICATION (ORB...ORB COMMUNICATION) CONTROLLER..................................................................................................................................................................................................1158 2. OVERVIEW...............................................................................................................................................................................................................................................................1159 2-1. APPLICABLE MODEL.................................................................................................................................................................................................................................................1159 2-2. BASIC CONFIGURATION..............................................................................................................................................................................................................................................1159 2-3. INSTALLATION DRAWING.............................................................................................................................................................................................................................................1162 3. STRUCTURE AND FUNCTION.................................................................................................................................................................................................................................................1164 3-1. VHMS CONTROLLER..................................................................................................................................................................................................................................................1164 3-2. BLOW-BY GAS SENSOR...............................................................................................................................................................................................................................................1164 3-3. ENGINE OIL TEMPERAUTRE SENSOR....................................................................................................................................................................................................................................1165 3-4. AMPLIFIER FOR EXHAUST GAS TEMPERATURE SENSOR.....................................................................................................................................................................................................................1166 3-5. COMMUNICATION (ORB...ORB COMMUNICATION) CONTROLLER/ANTENNA.......................................................................................................................................................................................................1167 4. TROUBLESHOOTING........................................................................................................................................................................................................................................................1168 4-1. TROUBLESHOOTING EQUIPMENT LIST...................................................................................................................................................................................................................................1168 4-2. CONNECTOR TYPES AND MOUNTING LOCATIONS...........................................................................................................................................................................................................................1169 4-3. CONNECTOR ARRANGEMENT DIAGRAM....................................................................................................................................................................................................................................1170 4-4. VHMS RELATED ELECTRICAL CIRCUIT DIAGRAM..........................................................................................................................................................................................................................1175 4-5. ERROR CODE LIST..................................................................................................................................................................................................................................................1177 4-6. STANDARD VALUE TABLE FOR ELECTRICAL PARTS........................................................................................................................................................................................................................1178 4-7. TROUBLE PHENOMENA LIST...........................................................................................................................................................................................................................................1179 HM-1: ABNORMALITY IN SATELLITE DATA TRANSMISSION......................................................................................................................................................................................................................1181 HM-2: ABNORMALITY IN DOWNLOADING OR SETTING WITH THE PC...............................................................................................................................................................................................................1182 HM-3: MANUAL SNAP HAS NOT BEEN RECORDED...............................................................................................................................................................................................................................1183 HM-4: ABNORMAL BLOW-BY GAS PRESSURE...................................................................................................................................................................................................................................1184 HM-5: ABNORMAL EXHAUST GAS TEMPERATURE................................................................................................................................................................................................................................1185 HM-6: ABNORMAL ENGINE OIL TEMPERATURE.................................................................................................................................................................................................................................1186 HM-7: ABNORMAL ENGINE OIL PRESSURE....................................................................................................................................................................................................................................1187 HM-8: ABNORMAL ENGINE SPEED...........................................................................................................................................................................................................................................1188 HM-9: ABNORMAL FUEL INJECTION AMOUNT..................................................................................................................................................................................................................................1189 HM-10: T/M DATE IS NOT DISPLAYED......................................................................................................................................................................................................................................1190 HM-11: WHILE TRAVELLING, TRAVEL VALVE SUDDENLY BECOMES NEUTRAL AND CANNOT TRAVEL......................................................................................................................................................................................1190 5. SETTING OF VHMS CONTROLLER.............................................................................................................................................................................................................................................1191 5-1. SETTING OF VHMS CONTROLLER.......................................................................................................................................................................................................................................1191 5-2. SETTING ITEM.....................................................................................................................................................................................................................................................1191 5-3. SETTING FLOW (OUTLINE)...........................................................................................................................................................................................................................................1191 5-4. CHECK OF OPERATION AND PERFORMANCE...............................................................................................................................................................................................................................1192 5-5. DATA COLLECTION..................................................................................................................................................................................................................................................1192 6. DATA RECOVERY AND TRANSMISSION.........................................................................................................................................................................................................................................1193 6-1. DATA RECOVERY....................................................................................................................................................................................................................................................1193 7. INSPECTION AND MAINTENANCE.............................................................................................................................................................................................................................................1200 7-1. INSPECTION TIMING: INSPECTION AND MAINTENANCE TIMING OF MACHINE..................................................................................................................................................................................................1200 7-2. INSPECTION ITEM..................................................................................................................................................................................................................................................1200 7-3. CORRECTIVE ACTION................................................................................................................................................................................................................................................1200 8. REPLACEMENT OF PARTS...................................................................................................................................................................................................................................................1200 8-1. IF INITIAL SET-UP OF VHMS SYSTEM HAS BEEN MADE OR VHMS CONTROLLER HAS BEEN REPLACED..............................................................................................................................................................................1200 8-2. WHEN COMMUNICATION CONTROLLER IS REPLACED........................................................................................................................................................................................................................1200 PROCEDURE Ⅰ FOR INITIAL SETUP OF VHMS.....................................................................................................................................................................................................................................1201 PROCEDURE Ⅱ FOR OPENING ORBCOMM SERVICE...................................................................................................................................................................................................................................1203
KOMATSU HD465-5,HD605-5 RIGID DUMP TRUCK SERVICE REPAIR WORKSHOP MANUAL – PDF DOWNLOAD:
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