Komatsu HD785-5 HD985-5 Dump Truck Shop Manual SEBM013917 PDF

Description

Komatsu HD785-5 HD985-5 Dump Truck Shop Manual SEBM013917 – PDF DOWNLOAD 

FILE DETAILS:

Komatsu HD785-5 HD985-5 Dump Truck Shop Manual SEBM013917 – PDF DOWNLOAD 

Language : English
Pages : 1392
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu HD785-5 HD985-5 Dump Truck Shop Manual SEBM013917 – PDF DOWNLOAD 

MACHINE MODEL   SERIAL NUMBER
HD785-5                   4001 and up
HD985-5                   1021 and up

COVER 1
CONTENTS 2
01 GENERAL 29
GENERAL ASSEMBLY DRAWING 30
SPECIFICATIONS 32
WEIGHT TABLE 35
LIST OF LUBRICANT AND COOLANT 36
10 STRUCTURE AND FUNCTION 37
RADIATOR, TORQUE CONVERTER COOLER 40
BRAKE OIL COOLER 41
POWER TRAIN SKELETON 42
OUTPUT SHAFT (HD785-5) 43
OUTPUT SHAFT (HD985-5) 44
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING 45
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM 46
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT SCHEMATICS 47
TORQUE CONVERTER 48
TORQUE CONVERTER VLAVE 50
LOCKUP SOLENOID VALVE 54
TRANSMISSION 55
TRANSMISSION VALVE 58
ECMV 59
LUBRICATION RELIEF VALVE 64
FRONT AXLE (HD785-5) 65
FRONT AXLE (HD985-5) 66
REAR AXLE (HD785-5) 68
REAR AXLE (HD985-5) 71
DIFFERENTIAL 72
DIFFERENTIAL LOCK CONTROL 74
DIFFERENTIAL LOCK SOLENOID VALVE 76
FINAL DRIVE (HD785-5) 77
FINAL DRIVE (HD985-5) 79
FRONT BRAKE 80
REAR BRAKE 81
PARKING BRAKE 85
WHEELS (HD785-5) 86
WHEELS (HD985-5) 87
AXLE SUPPORT (HD785-5) 88
AXLE SUPPORT (HD985-5) 89
STEERING SYSTEM 90
STEERING WHEEL (HD785-5) 91
STEERING WHEEL (HD985-5) 92
STEERING LINKAGE 93
SUSPENSION SYSTEM 95
SUSPENSION CYLINDER 97
REAR SUSPENSION CYLINDER 100
AIR PIPING 102
AIR CIRCUIT DIAGRAM 104
DESICCANT TYPE AIR DRIER (IF EQUIPPED) 106
AIR GOVERNOR 107
SAFETY VALVE 107
CHECK VALVE 108
DOUBLE CHECK VALVE 108
AUTO DRAIN VALVE 109
HAND BRAKE VALVE 110
BRAKE VALVE 111
EMERGENCY BRAKE CONTROL VALVE 112
PARKING BRAKE CONTROL VALVE 115
PARKING BRAKE PILOT VALVE 116
RELAY VLAVE 117
PARKING BRAKE RELAY VALVE 120
QUICK-RELEASE VALVE 122
PARKING BRAKE CHAMBER 122
RATIO VALVE (FOR FRONT BRAKE) 123
FRONT BRAKE CHAMBER 124
BRAKE CHAMBER 125
SLACK ADJUSTER 128
AIR DRIER (DESICCANT TYPE) (IF EQUIPPED) 129
HYDRAULIC PIPING 131
HYDRALUIC CIRCUIT DIAGRAM 133
DUMP BODY CONTROL 134
HYDRAULIC TANK AND BRAKE COOLING OIL TANK (HD785-5) 135
HYDRAULIC TANK AND BRAKE COOLING OIL TANK (HD985-5) 136
BRAKE COOLING OIL CONTROL VALVE (BCV) 137
STEERING VALVE 138
DEMAND VALVE 142
HOIST VALVE 146
CROSSOVER RELIEF VALVE 148
STEERING CYLINDER 149
HOIST CYLINDER 149
ELECTRICAL CIRCUIT DIAGRAM 150
STOP LAMP SWITCH 153
EXHAUST BRAKE SWITCH 153
TILT SWITCH 153
FRONT BRAKE CUT-OFF VALVE 154
OVERRUN PREVENTION VALVE 155
EXHAUST BRAKE VALVE 155
HORN VALVE 156
PARKING BRAKE SWITCH 156
AIR CONDITIONER 157
PIPING DIAGRAM 157
ELECTRICAL CIRCUIT DIAGRAM 158
REFRIGERANT CIRCUIT DIAGRAM 160
UNIT 161
RECEIVER DRYER 161
CONDENSER 162
COMPRESSOR 162
ENGINE CONTROL SYSTEM 163
SYSTEM DRAWING 163
ELECTRICAL CIRCUIT DIAGRAM 165
FUEL INJECTION PUMP ELECTRIC GOVERNOR 166
HYDRAULIC CIRCUIT DIAGRAM 167
AISS 167
SENSOR, SWITCHES 168
EXHAUST BRAKE 169
SYSTEM DIAGRAM 169
SYSTEM DIAGRAM 170
AUTOMATIC SHIFT CONTROL SYSTEM 172
SYSTEM DIAGRAM 172
ELECTRICAL CIRCUIT DIAGRAM 174
TRANSMISSION CONTROLLER 175
CONNECTOR SIGNALS 176
SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFTING RANGES 177
AUTOMATIC GEAR SHIFTING LINE GRAPH 178
SHIFT LEVER SWITCH 180
SENSORS, SWITCHES 181
TRANSMISSION OIL TEMPERATURE SENSOR 181
FILL SWITCH 182
ACCELERATOR SENSOR 183
SHIFT LIMIT SWITCH 184
MODE SELECTOR SWITCH 184
SELF-DIAGNOSTIC FUNCTION 185
AUTOMATIC EMERGENCY STEERING SYSTEM 186
SYSTEM DIAGRAM 186
ELECTRIC CIRCUIT DIAGRAM 187
FLOW SWITCH 188
RELAY TIMER 190
AUTOMATIC SUSPENSION SYSTEM 191
SYSTEM DIAGRAM 191
STRUCTURE OF SYSTEM 192
SYSTEM CIRCUIT DIAGRAM 193
AUTOMATIC SUSPENSION MODE SELECTION CONTROL 194
SUSPENSION CONTROLLER 195
SENSOR, SWITCHES 196
STEERING ANGLE SENSOR 196
PRESSURE SENSOR 196
SELF-DIAGNOSTIC FUNCTION 197
PAYLOAD METER (PRINTER TYPE) (OP) 198
STRUCTURE OF SYSTEM 198
ELECTRICAL CIRCUIT DIAGRAM 199
PAYLOAD METER BLOCK DIAGRAM 199
PRINCIPLE OF CALCULATION 200
FEATURES OF EQUIPMENT 202
1 PAYLOAD METER 202
2 PRESSURE SENSOR 205
3 CLINOMETER 206
4 LAMP DRIVE RELAY 206
SELF-DIAGNOSTIC FUNCTION 207
PAYLOAD METER Ⅱ (CARD TYPE) (OP) 208
STRUCTURE OF SYSTEM 208
ELECTRICAL CIRCUIT DIAGRAM 209
PAYLOAD METER BLOCK DIAGRAM 209
PRINCIPLE OF MEASUREMENT 210
FEATURE OF EACH DEVICE 211
1 PAYLOAD METER Ⅱ 211
2 PRESSURE SENSOR 239
3 CLINOMETER 240
4 LAMP DRIVE RELAY 240
5 SELF-DIAGNOSTIC FUNCTION 241
MACHINE MONITOR SYSTEM 247
SYSTEM DRAWING 247
MONITOR PANEL DIAGRAM 249
MACHINE MONITOR NORMAL DISPLAY FUNCTONS 250
SELF-DIAGNOSTIC FUNCTION WHEN STARTING SWITCH IS OPERATED 257
TRAVEL SPEED COMPENSATION ROTARY SWITCH 257
SENSORS, SWITCHES 258
ENGINE SPEED SENSOR 258
TRANSMISSION SPEED SENSOR 258
ENGINE OIL PRESSURE 259
ENGINE WATER TEMPERATURE SENSOR 260
RETARDER OIL TEMPERATURE SENSOR 260
TORQUE CONVERTER OIL TEMPERATURE SENSOR 260
AIR PRESSURE SENSOR 260
FUEL LEVEL SENSOR 261
TRANSMISSION OIL FILTER SENSOR 262
RADIATOR WATER LEVEL SENSOR 262
STEERING OIL TEMPERATURE SENSOR 263
BRAKE STROKE SENSOR 263
PMC SYSTEM (MACHINE EQUIPPED WITH ELECTRONIC GOVERNOR) (OP) 264
SYSTEM DIAGRAM 264
ELECTRIC CIRCUIT DIAGRAM 266
POWER TRAIN MANAGEMENT CONTROLLER (PMC) 267
MESSAGE DISPLAY (MOM) 269
SENSOR, SWITCHES 271
ENGINE SPEED SENSOR 271
TRANSMISSION SPEED SENSOR 271
ACCELERATOR SENSOR 272
SUSPENSION PRESSURE SENSOR 273
SENSORS, SWITCHES 274
ENGINE OIL LEVEL SENSOR 274
BRAKE OIL LEVEL SENSOR 274
HYDRAULIC OIL LEVEL SENSOR 275
RETARDER OIL LEVEL SENSOR 275
AIR CLEANER CLOGGING SENSOR 275
RETARDER BRAKE WEAR SENSOR 276
HYDRAULIC FILTER SENSOR 276
RETARDER OIL FILTER SENSOR 276
FULL-FLOW FILTER SENSOR 277
BATTERY ELECTROLYTE LEVEL SENSOR 277
MAINTENANCE MONITOR SYSTEM 278
SYSTEM DIAGRAM 278
MONITOR PANEL 279
MONITOR DISPLAY, FUNCTIONS 280
FUNCTIONS OF SWITCHES 282
SENSORS, SWITCHES 284
ENGINE OIL LEVEL SENSOR 284
RADIATOR WATER LEVEL SENSOR 284
TRANSMISSION OIL LEVEL SENSOR 284
HYDRAULIC OIL LEVEL SENSOR 285
RETARDER OIL LEVEL SENSOR 285
AIR FILTER CLOGGING SENSOR 285
RETARDER BRAKE WEAR SENSOR 286
HYDRAULIC FILTER SENSOR 286
RETARDER OIL FILTER SENSOR 286
TRANSMISSION OIL FILTER SENSOR 286
BATTERY ELECTROLYTE LEVEL SENSOR 287
TORQUE CONVERTER OIL TEMPERATURE SWITCH 287
RETARDER OIL TEMPERATURE SWITCH 287
ABS/ASR SYSTEM 288
SYSTEM CIRCUIT DIAGRAM 288
PRINCIPLE OF OPERATION 290
WHEN ABS IS ACTUATED 291
WHEN ASR IS ACTUATED 292
SYSTEM STRUCTURE DIAGRAM 293
ABS/ASR ELECTRICAL CIRCUIT DIAGRAM 295
ABS/ASR CONTROLLER (ECU) 297
ABS PRESSURE CONTROL VALVE 298
ASR CONTROL VALVE 301
WHEEL SPEED SENSOR 303
RELAY 303
ASR-Ⅱ SYSTEM (IF EUQIPPED) 304
SYSTEM DIAGRAM 304
BASIC OPERATION 305
SYSTEM CONFIGURATION 305
CONTROLLER OF AUTOMATIC SPIN REGULATOR 308
HYDRAULIC TANK PRESSURIZING SYSTEM (HIGH ALTITUDE SPECIFICATION) 309
ELECTRICAL CIRCUIT DIAGRAM OF HYDRAULIC TANK PRESSURIZING SYSTEM 311
AUTO-GREASING SYSTEM 312
ELECTRICAL CIRCUIT DIAGRAM OF AUTO-GREASING 315
AIR AND GREASE CIRCUIT DIAGRAM OF AUTO-GREASING 316
SOLENOID VALVE 317
REGULATOR 317
TIMER 318
20 TESTING AND ADJUSTING 319
STANDARD VALUE TABLE FOR ENGINE BELATED PARTS 320
STANDARD VALUE TABLE FOR CHASSIS 321
STANDARD VALUE TABLE FOR ELECTRICAL PARTS 327
TESTING AND ADJUSTING 341
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING 342
ADJUSTING VALVE CLEARANCE 344
MEASURING COMPRESSION PRESSURE 345
MEASURING BLOWBY PRESSURE 346
MEASURING BOOST PRESSURE 347
MEASURING EXHAUST TRMPERATURE 348
TESTING AND ADJUSTING FUEL INJECTION TIMING 349
ADJUSTING ALTERNATOR BELT TENSION 352
ADJUSTING ENGINE SPEED SENSOR 353
ADJSUTING TRANSMISSION SPEED SENSOR 353
ADJUSTING ACCELERATOR PEDAL 354
TESTING HYDRAULIC PRESSURE OF TORQUE CONVERTER VALVE 355
TESTING ECMV HYDRAULIC PRESSURE 356
TESTING TRANSMISSION LUBRICATION PRESSURE 359
TESTING TORQUE CONVERTER STALL SPEED 360
TESTING BRAKE PRESSURE 362
BLEEDING AIR FROM BRAKE CIRCUIT 363
TESTING WEAR OF FRONT BRAKE PAD 363
TESTING WEAR OF REAR BRAKE DISC 364
ADJUSTING PARKING BRAKE 366
TESTING BRAKE PERFORMANCE 367
TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER (WITH VARIABLE DAMPING FORCE SELECTOR VALVE) 368
TESTING AND ADJUSTING INVERTED TYPE REAR SUSPENSION CYLINDER 372
TESTING AND ADJUSTING SUSPENSION AIR CYLINDER 376
TESTING AND ADJUSTING AIR PRESSURE IN AIR CIRCUIT 377
INSPECTION OF AIR DRIER (DESICCANT TYPE) 378
ADJUSTING HOIST LEVER LINKAGE 380
ADJUSTING BODY POSITIONER 381
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING, HOIST CIRCUIT 382
AIR BLEEDING FROM STEERING CYLINDER 384
ADJUSTING ELECTRONIC MONITOR (SPEEDOMETER,TACHOMETER MODULE) 385
ADJUSTING Q [FUEL INJECTION AMOUNT] WHEN REPLACING ENGINE CONTROLLER 386
SETTING ROTARY SWITCH (MODEL DATA, NETWORK DATA) WHEN REPLACING TRANSMISSION CONTROLLER 387
METHOD OF DELETING DATA FROM ENGINE CONTROLER,TRANSMISSION CONTROLLER AND PMC MEMORY (CONTROL FROM MONITOR PANEL) 388
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM 391
PROCEDURE FOR OPERATING MODULATION CHECKER 397
ADJUSTING HYDRAULIC TANK PRESSURE (HIGH ALTITUDE SPECIFICATION) 402
PERFORMING PM CLINIC USING MANUAL SNAPSHOT (=QUICK PM) 403
PM-CLINIC SERVICE 407
TROUBLESHOOTING 409
POINTS TO REMEMBER WHEN TROUBLESHOOTING 410
SEQUENCE OF EVENTS IN TROUBLESHOOTING 411
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 412
CHECKS BEFORE TROUBLESHOOTING 420
TYPE OF CONNECTOR AND POSITION OF INSTALLATION 422
CONNECTOR PIN ALLOCATION CHART 428
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 433
EXPLANATIONS OF FUNCTIONS (CONTROL MECHANISM) OF ELECTRICAL SYSTEM 458
MONITOR PANEL USER CODES AND SERVICE MODE FUNCTION 465
SELF-DIAGNOSTIC DISPLAY METHOD FOR MONITOR PANEL AND CONTROLLERS 481
TABLE OF SERVICE CODES AND USER CODES 488
METHOD OF USING JUDGEMENT TABLE 498
METHOD OF USING TROUBLESHOOTING CHARTS 499
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (ELECTRONIC GOVERNOR SPECIFICATION G MODE) 501
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE 502
JUDGMENT TABLE FOR TRANSMISSION CONTROLLER, TRANSMISSION RELATED PARTS 510
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE CONTROLLER SYSTEM 514
G-1 C010 [E <–>1 0] ABNORMALITY IN POWER SOURCE 515
G-2 C011 [E <–>1 1] ABNORMALITY IN CONTROLLER 515
G-3 C012 [E <–>1 2] ABNORMALITY IN RACK SENSOR SYSTEM 516
G-4 C013 [E <–>1 3] ABNORMALITY IN RACK SENSOR SYSTEM LEFT BANK 517
G-5 C014 [E <–>1 4] ABNORMALITY IN GOVERNOR SOLENOID SYSTEM RIGHT BANK 518
G-6 C015 [E <–>1 5] ABNORMALITY IN GOVERNOR SOLENOID SYSTEM LEFT BANK 519
G-7 C016 [E <–>1 6] ABNORMALITY IN GOVERNOR CUT RELAY SYSTEM RIGHT BANK 520
G-8 C017 [E <–>1 7] ABNORMALITY IN GOVERNOR CUT RELAY SYSTEM LEFT BANK 521
G-9 C018 [E <–>1 8] ABNORMALITY IN RACK SENSOR POWER SOURCE SYSTEM 522
G-10 C019 [E <–>1 9] ABNORMALITY IN GOVERNOR SERVO SYSTEM RIGHT BANK 523
G-11 C01A [E <–>1 A] ABNORMALITY IN GOVERNOR SERVO SYSTEM LEFT BANK 523
G-12 C01b [E <–>1 b] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM A 524
G-13 C01C [E <–>1 C] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM B 525
G-14 C01d [E <–>1 d] ABNORMALITY IN PRE-STROKE SOLENOID SYSTEM RIGHT BANK 526
G-15 C01E [E <–>1 E] ABNORMALITY IN PRE-STROKE SOLENOID SYSTEM LEFT BANK 527
G-16 C021 [E <–>2 1] MISTAKEN CONNECTION OF CONNECTOR 528
G-17 C022 [E <–>2 2] ENGINE OVERRUN 529
G-18 C023 [E <–>2 3] ENGINE OVERHEATING 529
G-19 C024 [E <–>2 4] DROP IN ENGING OIL PRESSURE 529
G-20 C031 [E <–>3 1] ABNORMALITY IN ACCELERATION SENSOR SYSTEM 530
G-21 C034 [E <–>3 4] ABNORMALITY IN ENGINE COOLANT TEMPERATURE SYSTEM 533
G-22 C036 [E <–>3 6] ABNORMALITY IN ENGINE OIL PRESSURE SENSOR 534
G-23 C055 [E <–>5 5] ABNORMALITY IN NETWORK 535
G-24 C056 [E <–>5 6] ABNORMALITY IN SOLENOID POWER SOURCE SYSTEM RIGHT 536
G-25 C057 [E <–>5 7] ABNORMALITY IN SOLENOID POWER SOURCE SYSTEM LEFT 536
G-26 C058 [E <–>5 8] ABNORMALITY IN BACKUP POWER SOURCE SYSTEM 536
G-27 C059 [E <–>5 9] ABNORMALITY IN BACKUP POWER SOURCE SYSTEM 538
G-28 C0C2 [E <–>C 2] DEFECTIVE MODEL SELECTION DATA 539
G-29 C0C4 [E <–>C 4] ABNORMALITY IN ACCELERATION SENSOR SYSTEM 540
G-30 C0C5 [E <–>C 5] ABNORMALITY IN IDLE VALIDATION 543
G-31 ENGINE DOES NOT START 548
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) 551
METHOD OF USING TROUBLESHOOTING CHART 552
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 556
S-2 ENGINE DOES NOT START 558
a) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED) 558
b) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) 559
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 560
S-4 ENGINE STOPS DURING OPERATIONS 561
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 563
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER) 564
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) 565
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) 566
S-9 OIL BECOMES CONTAMINATED QUICKLY 567
S-10 FUEL CONSUMPTION IS EXCESSIVE 568
S-11 OIL IS IN COOLING, OR WATER SPURTS BACK, OR COOLANT LEVEL GOES DOWN 569
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) 570
S-13 OIL LEVEL RISES 571
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 572
S-15 ABNORMAL NOISE IS MADE 573
S-16 VIBRATION IS EXCESSIVE 575
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A MODE) 576
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 580
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE 582
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER, TRANSMISSION RELATED PARTS 602
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM 604
A-1 ABNORMALITY IN POWER SOURCE SYSTEM 606
a) [u u][OFF]CONTROLLER SELF-DIAGNOSTIC DISPLAY LED DOES NOT LIGHT UP 606
b) bOO1 [E <–>0 1, E C<–>0 1] DROP IN VOLTAGE OF CONTROLLER POWER SOURCE IS DISPLAYED 607
c) bOdA [E <–>d A, E C<–>d A] DROP IN VOLTAGE OF BATTERY DIRECT POWER SOURCE IS DISPLAYED 608
d) bOdb [E <–>d b, E C<–>d b] DROP IN VOLTAGE OF MAIL POWER SOURCE IS DISPLAYED 609
e) bOO2 [E <–>0 2, E C<–>0 2] ABNORMALITAY IN TRANSMISSION CUT RELAY POWER SOURCE IS DISPLAYED 610
A-2 bOO3 [E <–>0 3, E C<–>0 3] ABNORMALITY IN NEUTRAL SAFETY SYSTEM IS DISPLAYED 611
A-3 bOO5 [E <–>0 5, E C<–>0 5] DOUBLE ENGAGEMENT FOR CLUTCH IS DISPLAYED 612
A-4 bOO6 [E <–>0 6, E C<–>0 6] ABNORMALITY IN TRANSMISSION [CUT RELAY] SYSTEM DISPLAYED 613
A-5 bOO8 [E <–>0 8, E C<–>0 8] ABNORMALITY IN REAR BRAKE SOLENOID SYSTEM IS DISPLAYED 614
A-6 bOO9 [E <–>0 9, E C<–>0 9] ABNORMALITY IN EXHAUST BRAKE SOLENOID SYSTEM IS DISPLAYED 615
A-7 616
a) bOC4 [E <–>C 4, E C<–>C 4] SHORT CIRCUIT WITH GROUND IN BCV REAR SOLENOID IS DISPLAYED 616
b) bOC6 [E <–>C 6, E C<–>C 6] SHORT CIRCUIT IN BCV REAR SOLENOID IS DISPLAYED 617
c) bOC8 [E <–>C 8, E C<–>C 8] DISCONNECTION IN BCV REAR SOLENOID IS DISPLAYED 618
A-8 ABNORMALITY IN SPEED SENSOR SYSTEM 619
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) 619
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 621
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 622
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 623
A-9 SPEED SENSOR SYSTEM, CLUTCH SLIPPING 624
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 624
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 625
A-10 ABNORMALITY IN MODEL SELECTION (WIRING HARNESS) IS DISPLAYED 626
a) b014 [E <–>1 4, E C<–>1 4] ABNORMALITY IN MODEL SELECTION (WIRING HARNESS) IS DISPLAYED 626
b) b0A1 [E <–>A 1, E C<–>A 1] ABNORMALITY IN MODEL SELECTION (ROTARY SWITCH) IS DISPLAYED 627
A-11 ABNORMALITY IN SHIFT LEVER SYSTEM 628
a) b007 [E <–>0 7, E C<–>0 7] SHORT CIRCUIT IN SHIFT LEVER ASSEMBLY POWER SOURCE IS DISPLAYED 628
b) b015 [E <–>1 5, E C<–>1 5] SHIFT LEVER POSITION SIGNAL INPUT FOR 2 OR MORE SYSTEM IS DISPLAYED 629
c) b016 [E <–>1 6, E C<–>1 6] SHIFT LEVER POSITION SIGNAL IS NOT INPUT 631
A-12 b017 [E <–>1 7, E C<–>1 7] ABNORMALITY IN ACCELERATOR SIGNAL IS DISPLAYED 633
A-13 b019 [E <–>1 9, E C<–>1 9] ABNORMALITY IN TRANSMISSION OIL TRMPERATURE SENSOR IS DISPLAYED 634
A-14 ABNORMALITY IN PRESSURE CONTROL VALVE SYSTEM 635
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 635
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 637
b-1) INSPECTING FILL SIGNAL SYSTEM 637
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) 638
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) 638
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) 639
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 640
A-17 ABNORMALITY IN SENSOR SYSTEM 642
a) b0A2 [E <–>A 2, E C<–>A 2] ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE SENSOR SYSTEM IS DISPLAYED 642
b) b0A3 [E <–>A 3, E C<–>A 3] ABNORMALITY IN FUEL LEVEL SENSOR SYSTEM IS DISPLAYED 643
c) b0b2 [E <–>b 2, E C<–>b 2] ABNORMALITY IN COOLANT TEMPERATURE SENSOR SYSTEM IS DISPLAYED 644
d) b0b3 [E <–>b 3, E C<–>b 3] ABNORMALITY IN AIR PRESSURE SENSOR SYSTEM IS DISPLAYED 645
e) b0b4 [E <–>b 4, E C<–>b 4] ABNORMALITY IN RETARDER BRAKE OIL TEMPERATURE SENSOR IS DISPLAYED 646
A-18 WARNING DISPLAY 647
a) b0d1 [E <–>d 1, E C<–>d 1] TRANSMISSION FILTER CLOGGED WARNING IS DISPLAYED 647
b) b0d5 [E <–>d 5, E C<–>d 5] TILT WARNING IS DISPLAYED 648
c) b0d6 [E <–>d 6, E C<–>d 6] DROP IN RADIATOR WATER LEVEL WARNING IS DISPLAYED 649
d) b0d7 [E <–>d 7, E C<–>d 7] BATTERY CHARGE LEVEL WARNING IS DISPLAYED 650
e) b0E5 [E <–>E 5, E C<–>E 5] STEERING OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED 651
f) b0F5 [E <–>F 5, E C<–>F 5] DROP IN ENGINE OIL PRESSURE WARNING IS DISPLAYED (MECHANICAL GOVERNOR SPECIFICATION MACHINE) 652
g) b0F6 [E <–>F 6, E C<–>F 6] REAR BRAKE OIL PRESSURE WARNING IS DISPLAYED 653
A-19 b0b7 [E <–>b 7, E C<–>b 7] ABNORMALITY IN ENGINE OIL PRESSURE SYSTEM SENSOR IS DISPLAYED (MECHANICAL GOVERNOR SPECIFITION MACHINE) 654
A-20 b0C1 [E <–>C 1, E C<–>C 1] ABNORMALITY IN CONNECTOR CONNECTION IS DISPLAYED 655
A-21 656
a) b0d2 [E <–>d 2, E C<–>d 2] TORQUE CONVERTER OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED 656
b) b0d3 [E <–>d 3, E C<–>d 3] ENGINE COOLANT TEMPERATURE OVERHEAT WARNING IS DISPLAYED 656
c) b0E9 [E <–>E 9, E C<–>E 9] AIR PRESSURE DROP WARNING IS DISPLAYED 656
d) b0F3 [E <–>F 3, E C<–>F 3] RETARDER BRAKE OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED 656
e) b0d8 [E <–>d 8, E C<–>d 8] ENGINE OVERRUN ACTUATED IS DISPLAYED 657
f) b0d9 [E <–>d 9, E C<–>d 9] ENGINE OVERSHOOT ACTUATED IS DISPLAYED 657
TROUBLESHOOTING OF SUSPENSION CONTROLLER SYSTEM (SP MODE) 658
JUDGMENT TABLE FOR SUSPENSION CONTROLLER, SUSPENSION RELATED PARTS 659
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE 661
ELECTRICAL CIRCUIT DIAGRAM OF SUSPENSION CONTROLLER SYSTEM 665
SP-1 d001 [ALL OFF or E <–>01] ABNORMALITY IN POWER SOURCE IS DISPLAYED 667
SP-2 d011 [E <–>11 IS DISPLAYED] ABNORMALITY IN PRESSURE SENSOR [RIGHT] SYSTEM IS DISPLAYED 668
SP-3 d012 [E <–>12 IS DISPLAYED] ABNORMALITY IN PRESSURE SENSOR [LEFT] SYSTEM IS DISPLAYED 669
SP-4 d015 [E <–>15 IS DISPLAYED] ABNORMALITY IN TRAVEL SPEED SENSOR SYSTEM IS DISPLAYED 670
SP-5 d016 [E <–>16 IS DISPLAYED] ABNORMALITY IN STEERING SENSOR SYSTEM IS DISPLAYED 671
SP-6 d0C2 [E <–>C2 IS DISPLAYED] DEFECTIVE MODEL SELECTION DATA IS DISPLAYED 672
SP-7 d021 [E <–>21 IS DISPLAYED] ABNORMALITY IN SOLENOID [1] SYSTEM IS DISPLAYED 673
SP-8 d022 [E <–>22 IS DISPLAYED] ABNORMALITY IN SOLENOID [2] SYSTEM IS DISPLAYED 674
SP-9 d023 [E <–>23 IS DISPLAYED] ABNORMALITY IN SOLENOID [3] SYSTEM IS DISPLAYED 675
SP-10 d0C1 [E <–>C1 IS DISPLAYED] DISCONNECTION IN NETWROK IS DISPLAYED 676
SP-11 d0C3 [E <–>C3 IS DISPLAYED] DEFECTIVE TRAVEL SPEED COMPENSATION DATA IS DISPLAYED 677
TROUBLESHOOTING OF PAYLOAD METER (PRINTER TYPE) SYSTEM (LP MODE) 678
SERVICE CODES AND SELF-DIAGNOSIS OF PAYLOAD METER (PRINTER TYPE) 679
ELECTRIC CIRCUIT DIAGRAM FOR PAYLOAD METER (PRINTER TYPE) SYSTEM 680
LP-1 NO DISPLAY APPEARS WHEN STARTING SWITCH IS TURNED ON 682
LP-2 CALIBRATION DEMAND (CAL FLASHES) IS SHOWN CONTINUOUSLY AFTER STARTING SWITCH IS TURNED ON 683
LP-3 CALIBRATION CANNOT BE CARRIED OUT 685
LP-4 AFTER STARTING SWITCH IS TURNED ON,ALL EXTERNAL DISPLAY LAMPS DO NOT LIGHT UP 688
LP-5 CONDITION DOES NOT EXIST FOR LAMPS TO LIGHT UP,BUT EXERNAL DISPLAY LAMPS LIGHT UP 690
LP-6 LEVEL OF LIGHTING UP OF EXTERNAL DISPLAY LAMPS IS NOT CORRECT 691
LP-7 ABNORMALITY IN DISPLAY LOGIC 693
LP-8 E01-E04 IS DISPLAYED 698
LP-9 E11-E14 IS DISPLAYED 699
LP-10 E21-E28 IS DISPLAYED BY SENSOR CHECK 700
LP-11 E31 IS DISPLAYED 701
LP-12 E32 IS DISPLAYED 703
LP-13 E41 IS DISPLAYED 705
LP-14 E42 IS DISPLAYED 706
LP-15 PRINTER DOES NOT PRINT ANYTHING (BLANK PAPER COMES OUT) 707
LP-16 PRINTER PRINTS ONLY “NO DATA” 707
LP-17 PRINTER DOES NOT PRINT OUT WHEN PRT SWITCH IS PRESSED 707
LP-18 “PAPE” FLASHES 708
LP-19 TIME IS WRONG 708
LP-20 E33 IS DISPLAYED 708
TROUBLESHOOTING OF PAYLOAD METER Ⅱ (CARD TYPE) SYSTEM (LC MODE) 709
SERVICE CODES AND SELF-DIAGNOSIS OF PAYLOAD METER Ⅱ (CARD TYPE) 710
ELECTRICAL CIRCUIT DIAGRAM FOR PAYLOAD METER Ⅱ (CARD TYPE) SYSTEM 713
LC-1 NO DISPLAY APPEARS WHEN STARTING SWITCH IS TURNED ON 715
LC-2 AFTER STARTING SWITCH IS TURNED ON,ALL EXTERNAL DISPLAY LAMPS DO NOT LIGHT UP 716
LC-3 CONDITION DOES NOT EXIST FOR LAMPS TO LIGHT UP,BUT EXTERNAL DISPLAY LAMPS LIGHT UP 717
LC-4 LEVEL OF LIGHTING UP OF EXTERNAL DISPLAY LAMPS IS NOT CORRECT 718
LC-5 CYCLE DATA IS NOT RECOREDE,ON/OFF DATA IS NOT RECORDED:BATTERY CHARGE SIGNAL SYSTEM:ENGINE IS NOT STARTED IS DETECTED 720
LC-6 CALIBRATION CANNOT BE CARRIED OUT,TIME DISPLAY DOES NOT MATCH CONDITIONS:SHIFT LEVER N POSITION SIGNAL SYSTEM 721
LC-7 ABNORMALITY IN DISPLAY LOGIC 722
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 724
LC-9 F-09 IS DISPLAYED:DROP IN VOLTAGE OF BACK-UP BATTERY BUILT INTO PAYLOAD METER 725
LC-10 FULL DISPLAY APPEARS 725
LC-11 F-20 IS DISPLAYED:SENSOR POWER SOURCE VOLTAGE SYSTEM 726
LC-12 F-21 – F-24 IS DISPLAYED:DISCONNECTION,SHORT CIRCUIT WITH GROUND SUSPENSION PRESSURE SENSOR SYSTEM 727
LC-13 F-25 – F-28 IS DISPLAYED:SHORT CIRCUIT IN SUSPENSION PRESSURE SENSOR SYSTEM POWER SOURCE 729
LC-14 F CAL IS DISPLAYED:CALIBRATION NOT CARRIED OUT,DAMAGED DATA INSIDE PAYLOAD METER 730
LC-15 F-41 – F-45 IS DISPLAYED:SHORT CIRCUIT IN EXTERNAL DISPLAY LAMP SYSTEM POWER SOURCE 731
LC-16 L-BAD IS DISPLAYED:CYCLE DATA SAVED WHEN MACHINE WAS SWAYING 733
LC-17 MACHINE IS NOT LOADING BUT EXTERNAL DISPLAY LAMPS GIVE LOAD ESTIMATE DISPLAY AFTER LOADING,DISPLAY SWITCHES TO TIME DISPLAY BEFORE TRAVELING 160m 734
LC-18 F-31 IS DISPLAYED:DISCONNECTION,SHORT CIRCUIT WITH GROUND IN CLINOMETER SYSTEM 735
LC-19 F-32 IS DISPLAYED:SHORT CIRCUIT WITH CLINOMETER SYSTEM POWER SOURCE 736
LC-20 F-18 IS DISPLAYED:DISCONNECTION IN BATTERY CHARGE SIGNAL 737
LC-21 F-93 – 99 ARE DISPLAYED:ABNORMALITY IN NETWORK (WHEN PMC IS INSTALLED) 738
LC-22 F-71,73,80,91,92 ARE DISPLAYED:(WHEN PMC,TALKS ARE INSTALLED) 739
TROUBLESHOOTING OF ARSC [AUTOMATIC RETARDER SPEED CONTROLLER] SYSTEM (R MODE) 740
OUTLINE 741
ELECTRICAL CIRCUIT DIAGRAM FOR ARSC (AUTOMATIC RETARDER SPEED CONTROLLER) SYSTEM 745
R-1 0 1 (ABNORMALITY IN POWER SOURCE VOLTAGE) IS DISPLAYED 747
R-2 1 0 (DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED 748
R-3 1 3 (DISCONNECTION IN TRANSMISSION OUTPUT SHAFT SPEED SENSOR SYSTEM) IS DISPLAYED 749
R-4 1 5 (FAILURE IN RETARDER OIL TEMPERATURE SENSOR SYSTEM) IS DISPLAYED 750
R-5 1 7 (FAILURE IN ACCELERATOR SIGNAL SYSTEM) IS DISPLAYED 751
R-6 1 8 (FAILURE IN SUSPENSION PRESSURE SENSOR “LEFT” SYSTEM) IS DISPLAYED 752
R-7 1 9 (FAILURE IN SUSPENSION PRESSURE SENSOR “RIGHT” SYSTEM) IS DISPLAYED 753
R-8 4 2 (DISCONNECTION IN EXHAUST BRAKE SELECTOR SIGNAL SYSTEM) IS DISPLAYED 754
R-9 4 3 (DISCONNECTION IN ARSC CAUTION LAMP SYSTEM) IS DISPLAYED 755
R-10 4 4 (DISCONNECTION IN READY LAMP SYSTEM) IS DISPLAYED 756
R-11 4 5 (DISCONNECTION IN PANEL CAUTION AND BUZZER SYSTEM) IS DISPLAYED 757
R-12 5 2 (SHORT CIRCUIT WITH GROUND EXHAUST BRAKE SELECTOR SIGNAL OUTPUT SYSTEM) IS DISPLAYED 758
R-13 5 3 (SHORT CIRCUIT WITH GROUND IN ARSC CAUTION LAMP SYSTEM) IS DISPLAYED 759
R-14 5 4 (SHORT CIRCUIT WITH GROUND IN READY OUTPUT CIRCUIT SYSTEM) IS DISPLAYED 760
R-15 5 5 (SHORT CIRCUIT WITH GROUND IN PANEL CAUTION LAMP AND BUZZER OUTPUT SYSTEM) IS DISPLAYED 761
R-16 6 0 (FAILURE IN ENGINE SPEED SYSTEM) IS DISPLAYED 762
R-17 7 0 (DISCONNECTION IN TRAVEL SPEED DISPLAY UP OUTPUT SYSTEM) IS DISPLAYED 763
R-18 7 1 (DISCONNECTION IN TRAVEL SPEED DISPLAY DOWN OUTPUT SYSTEM) IS DISPLAYED 764
R-19 7 2 (DISCONNECTION IN TRAVEL SPEED DISPLAY CLEAR OUTPUT SYSTEM) IS DISPLAYED 765
R-20 7 3 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY UP OUTPUT SYSTEM) IS DISPLAYED 766
R-21 7 4 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY DOWN OUTPUT SYSTEM) IS DISPLAYED 767
R-22 7 5 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY CLEAR OUTPUT SYSTEM) IS DISPLAYED 768
R-23 8 1 (SHORT CIRCUIT WITH GROUND IN PRESSURE CONTROL VALVE SYSTEM) IS DISPLAYED 769
R-24 8 3 (DISCONNECTION IN PRESSURE CONTROL VALVE SYSTEM) IS DISPLAYED 770
R-25 8 5 (FAILURE IN PRESSURE CONTROL VALVE (PRESSURE CONTROL VALVE REMAINS OPEN)) IS DISPLAYED 771
R-26 8 7 (FAILURE IN PRESSURE CONTROL VALVE (PRESSURE CONTROL VALVE DOES NOT OPEN)) IS DISPLAYED 772
R-27 8 9 (SHORT CIRCUIT WITH GROUND IN PRESSURE SWITCH VALVE SYSTEM) IS DISPLAYED 773
R-28 9 0 (DISCONNECTION IN PRESSURE SWITCH VALVE SYSTEM) IS DISPLAYED 774
R-29 9 1 (FAILURE IN PRESSURE SWITCH VALVE SYSTEM (REMAINS OPEN)) IS DISPLAYED 775
R-30 9 2 (FAILURE IN PRESSURE SWITCH VALVE SYSTEM (DOES NOT OPEN)) IS DISPLAYED 776
R-31 9 3 (DISCONNECTION IN SYSTEM SWITCH SYSTEM) IS DISPLAYED 777
R-32 9 4 (SHORT CIRCUIT WITH GROUND IN SYSTEM SWITCH SYSTEM) IS DISPLAYED 778
R-33 9 5 (DISCONNECTION,SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED SETTING SWITCH SYSTEM) IS DISPLAYED 779
R-101 SET SPEED CANNOT BE SET 780
R-102 FAILURE CODE IS ALWAYS CLEARED (CONTROLLER DISPLAY WINDOW ALWAYS SHOWS “–“) OR FAILURE CODE CANNOT BE CLEARED 783
R-103 EFFECT OF RETARDER IS TOO STRONG WHEN MACHINE IS EMPTY,OR TOO WEAK WHEN MACHINE IS LOADED (DOES NOT JUDGE LOADED/UNLOADED CONDITION PROPERLY) 784
R-104 ABNORMALITY APPEARS IN OTHER CONTROLLER 784
R-105 WHEN TRAVELING DOWNHILL,EVEN WHEN SET SPEED IS EXCEEDED,NO CONTROL IS CARRIED OUT 785
R-106 MONITOR LAMP (BUZZER) STAYS ON (OR OFF) 786
R-107 READY LAMP DOES NOT LIGHT UP (OR STAYS LIGHTED UP) 787
R-108 EXHAUST BRAKE DOES NOT WORK PROPERLY 789
R-109 THERE IS DIFFERENCE BETWEEN TRAVEL SPEED ROD VALUE AND ACTUAL MACHINE VALUE 791
R-110 RETARDER LAMP DOES NOT LIGHT UP,OR STAYS LIGHTED UP 794
R-111 TRAVEL SPEED DISPLAY ALWAYS GIVES DISPLAY (OR DOES NOT GIVE ANY DISPLAY) 795
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) 796
H-1 MACHINE DOES NOT START 797
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY 799
H-3 LOCK-UP CLUTCH CANNOT BE DISENGAGED 799
H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING 800
H-5 TRANSMISSION DOES NOT SHIFT UP 800
H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING 801
H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR 805
H-8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH 807
H-9 TORQUE CONVERTER OIL PRESSURE IS LOW 808
H-10 FRONT BRAKE IS INEFFECTIVE,OR EFFECTIVE ONLY ON ONE SIDE 809
H-11 REAR BRAKE IS INEFFECTIVE,OR EFFECTIVE ONLY ON ONE SIDE 810
H-12 STEERING WHEEL IS HEAVY 811
H-13 STEERING WHEEL DOES NOT WORK 812
H-14 STEERING WHEEL VIBRATES 812
H-15 HOIST CYLINDER LACKS LIFTING FORCE (LIFTING SPEED) 813
H-16 HOIST CYLINDER DOES NOT WORK 814
H-17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY 815
H-18 AIR PRESSURE DOES NOT RISE 816
TROUBLESHOOTING OF MONITOR PANEL SYSTEM (P MODE) 817
METHOD OF SELF-DIAGNOSTIC DISPLAY FOR MONITOR PANEL AND CONTROLLERS 819
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE (MONITOR PANEL SYSTEM) 820
ELECTRICAL CIRCUIT DIAGRAM FOR MONITOR PANEL SYSTEM 824
P-1 CHECK PATTERN FOR WIRING HARNESSES BETWEEN MODULES 826
P-2 NOTHING ON MONITOR PANEL WORKS 830
P-3 LH,RH MODULE AND FUEL GAUGE DO NOT WORK 831
P-4 LH,RH MODULE AND FUEL GAUGE DO NOT WORK 832
P-5 RH MODULE DOES NOT WORK 833
P-6 LH MODULE DOES NOT WORK 834
P-7 TRAVEL CALCULATOR DOES NOT WORK 835
P-8 SERVICE METER DISPLAY DOES NOT WORK CORRECTLY 836
P-9 CENTRAL WARNING LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS FAILURE CODE [A002] 837
P-10 CENTRAL WARNING LAMP STAYS LIGHTED UP 838
P-11 ALARM BUZZER DOES NOT WORK,OR MONITOR PANEL DETECTS FAILURE CODE [A003] 839
P-12 ALARM BUZZER CONTINUES TO SOUND 840
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] 841
P-14 SUSPENSION MODE,POWER/ECONOMY MODE DISPLAYS ARE ABNORMAL (NOTHING IS DISPLAYED,OR DISPLAY DOES NOT CHANGE),OR MONITOR PANEL DETECTS SEVICE CODE [A016] 842
P-15 GAUGE DISPLAYS ARE ABNORMAL (NOTHING IS DISPLAYED,OR DISPLAY DOES NOT CHANGE) 843
P-16 COOLANT LEVEL DROP CAUTION LAMPS DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001] 844
P-17 COOLANT LEVEL DROP CAUTION LAMP STAYS LIGHTED UP 845
P-18 EMERGENCY STEERING PILOT LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SEVICE CODE [A001] 846
P-19 EMERGENCY STEERING PILOT LAMP STAYS LIGHTED UP 847
P-20 ENGINE OIL PRESSURE DROP CAUTION LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001] 848
P-21 ENGINE OIL PRESSURE DROP CAUTION LAMP STAYS LIGHTED UP 849
P-22 EXHAUST BRAKE PILOT LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001] 850
P-23 EXHAUST BRAKE PILOT LAMP STAYS LIGHTED UP 851
P-24 CHARGING CIRCUIT ABNORMALITY CAUTION LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001] 852
P-25 CHARGING CIRCUIT ABNORMALITY CAUTION LAMP STAYS LIGHTED UP 853
P-26 TRANSMISSION FILTER CLOGGING CAUTION LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001] 854
P-27 TRANSMISSION FILTER CLOGGING CAUTION LAMP STAYS LIGHTED UP 855
P-28 BRAKE STROKE CAUTION LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001] 856
P-29 BRAKE STROKE CAUTION LAMP STAYS LIGHTED UP 857
P-30 PREHEATING SWITCH PILOT LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001] 858
P-31 PREHEATING SWITCH PILOT LAMP STAYS LIGHTED UP 859
P-32 TILT WARNING LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001] 860
P-33 TILT WARNING LAMP STAYS LIGHTED UP 861
P-34 BODY FLOAT (EXCEPT FLOAT) PILOT LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001] 862
P-35 BODY FLOAT (EXCEPT FLOAT) PILOT LAMP STAYS LIGHTED UP 863
P-36 REAR BRAKE PILOT LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001] 864
P-37 REAR BRAKE PILOT LAMP STAYS LIGHTED UP 865
P-38 PARKING BRAKE PILOT LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001] 866
P-39 PARKING BRAKE PILOT LAMP STAYS LIGHTED UP 867
P-40 MAINTENANCE CAUTION LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001] 868
P-41 MAINTENANCE CAUTION LAMP STAYS LIGHTED UP 869
P-42 STEERING OIL TEMPERATURE CAUTION LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001] 870
P-43 STEERING OIL TEMPERATURE CAUTION LAMP STAYS LIGHTED UP 871
P-44 DIFFERENTIAL LOCK PILOT LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001] 872
P-45 DIFFERENTIAL LOCK PILOT LAMP STAYS LIGHTED UP 873
P-46 HIGH BEAM DISPLAY DOES NOT LIGHT UP 874
P-47 TURN SIGNAL LAMP (RIGHT) DOES NOT LIGHT UP 876
P-48 TURN SIGNAL LAMP (LEFT) DOES NOT LIGHT UP 877
P-49 LAMP CHECK SWITCH DOES NOT WORK 878
P-50 AISS SWITCH DOES NOT WORK 879
P-51 EXHAUST BRAKE SWITCH DOES NOT WORK 880
P-52 MODE CHANGE SWITCH (1) DOES NOT WORK 881
P-53 MODE CHANGE SWITCH (2) DOES NOT WORK 882
P-54 KPH/MPH SPEEDOMETER UNIT SELECTOR DOES NOT WORK 883
P-55 DEFECTIVE OPERATION OF ALL SWITCH INPUTS 884
P-56 MONITOR PANEL DETECTS SERVICE CODES [A014] OR [A019] 885
P-57 MONITOR PANEL DETECTS SERVICE CODE [A015] 886
P-58 MONITOR PANEL DETECTS SERVICE CODE [A011] 887
P-59 MONITOR PANEL DETECTS SERVICE CODE [A012] 887
P-60 MONITOR PANEL DETECTS SERVICE CODE [A000] 887
TROUBLESHOOTING OF PMC SYSTEM (M MODE) 888
PMC RELATED ELECTRIC CIRCUIT DIAGRAM 890
M-1 PMC DOES NOT WORK 892
M-2 E002 [0 2:FLASHES] FAILURE IN NV RAM DATA IS DISPLAYED 893
M-3 E002 [0 2:FLASHES] DROP IN BATTERY DIRECT POWER SOURCE VOLTAGE IS DISPLAYED 894
M-4 E003 [0 3:FLASHES] ABNROMALITY IN CONNECTOR CONNECTION IS DISPLAYED 896
M-5 E011 [1 1:FLASHES] DISCONNECTION IN GSP COMMUNICATIONS IS DISPLAYED 897
M-5 E012 [1 2:FLASHES] ABNORMALITY IN GSP COMMUNICATIONS IS DISPLAYED 897
M-6 E013 [1 3:FLASHES] DISCONNECTION IN MOM COMMUNICATIONS IS DISPLAYED 898
M-6 E014 [1 4:FLASHES] ABNORMALITY IN MOM COMMUNICATIONS IS DISPLAYED 898
M-7 E015 [1 5:FLASHES] DISCONNECTION IN TMS COMMUNICATIONS IS DISPLAYED 899
M-7 E016 [1 6:FLASHES] ABNORMALITY IN TMS COMMUNICATIONS IS DISPLAYED 899
M-8 E017 [1 7:FLASHES] DISCONNECTION IN CENSE COMMUNICATIONS IS DISPLAYED 899
M-8 E018 [1 8:FLASHES] ABNORMALITY IN CENSE COMMUNICATIONS IS DISPLAYED 899
M-9 E026 [2 6:FLASHES] COMMUNICATIONS ABNORMALITY 1 IS DISPLAYED 900
M-9 E027 [2 7:FLASHES] COMMUNICATIONS ABNORMALITY 2 IS DISPLAYED 900
M-9 E028 [2 8:FLASHES] COMMUNICATIONS ABNORMALITY 3 IS DISPLAYED 900
M-9 E029 [2 9:FLASHES] COMMUNICATIONS ABNORMALITY 4 IS DISPLAYED 900
M-9 E02A [2 A:FLASHES] COMMUNICATIONS ABNORMALITY 5 IS DISPLAYED 900
M-10 E035 [3 5:FLASHES] ABNORMALITY IN IDLE VALIDATION IS DISPLAYED 902
M-11 E041 [4 1:FLASHES] SHORT CIRCUIT WITH GROUND/DISCONNECTION IN SUSPENSION PRESSURE SENSOR (RIGHT) SYSTEM IS DISPLAYED 904
M-11 E042 [4 2:FLASHES] SHORT CIRCUIT WITH GROUND/DISCONNECTION IN SUSPENSION PRESSURE SENSOR (LEFT) SYSTEM IS DISPLAYED 904
M-11 E043 [4 3:FLASHES] SHORT CIRCUIT IN SUSPENSION PRESSURE SENSOR (RIGHT) SYSTEM IS DISPLAYED 904
M-11 E044 [4 4:FLASHES] SHORT CIRCUIT IN SUSPENSION PRESSURE SENSOR (LEFT) SYSTEM IS DISPLAYED 904
M-12 E054 [5 4:FLASHES] DISCONNECTION IN ACCELERATOR SIGNAL SYSTEM IS DISPLAYED 905
M-13 E055 [5 5:FLASHES] SHORT CIRCUIT IN ACCELERATOR CELL SIGNAL SYSTEM IS DISPLAYED 906
M-14 E056 [5 6:FLASHES] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED 907
M-15 E057 [5 7:FLASHES] ABNORMALITY IN INPUT SHAFT SPEED SENSOR SYSTEM IS DISPLAYED 908
M-16 E058 [5 8:FLASHES] ABNORMALITY IN TRAVEL SPEED SENSOR (TRANSMISSION OUTPUT SHAFT SPEED SENSOR) IS DISPLAYED 909
M-17 E0A1 [A 1:FLASHES] WHEN ENGINE IS NOT RUNNING,DROP IN BRAKE OIL LEVEL IS DISPLAYED 910
M-18 E0A2 [A 2:FLASHES] WHEN ENGINE IS NOT RUNNING,DROP IN RETARDER OIL LEVEL IS DISPLAYED 911
M-19 E0A3 [A 3:FLASHES] WHEN ENGINE IS NOT RUNNING,DROP IN HYDRAULIC OIL LEVEL IS DISPLAYED 912
M-20 E0A6 [A 6:FLASHES] WHEN ENGINE IS RUNNING,RETARDER FILTER CLOGGED IS DISPLAYED 913
M-21 E0A7 [A 7:FLASHES] WHEN ENGINE IS RUNNING,FULL-FLOW FILTER CLOGGED IS DISPLAYED 914
M-22 E0A8 [A 8:FLASHES] WHEN ENGINE IS RUNNING,HYDRAULIC FILTER CLOGGED IS DISPLAYED 915
M-23 E0b2 [b 2:FLASHES] AT NEUTRAL,RIHGT RETARDER BRAKE DISC WEAR IS DISPLAYED 916
M-24 E0b3 [b 3:FLASHES] AT NEUTRAL,LEFT RETARDER BRAKE DISC WEAR IS DISPLAYED 917
M-25 E0b4 [b 4:FLASHES] WHEN ENGINE IS NOT RUNNING,DROP IN BATTERY ELECTROLYTE LEVEL IS DISPLAYED 918
M-26 E0b5 [b 5:FLASHES] WHEN ENGINE IS NOT RUNNING, DROP IN ENGINE OIL LEVEL IS DISPLAYED 919
M-27 E0b6 [b 6:FLASHES] WHEN ENGINE IS RUNNING,AIR CLEANER CLOGGED IS DISPLAYED 920
M-28 E0C1 [C 1:FLASHES] ABNORMALITY IN NETWORK SYSTEM IS DISPLAYED 921
M-28 E0C2 [C 2:FLASHES] ABNORMALITY IN MODEL SELECTION DATA IS DISPLAYED 921
M-29 E0C3 [C 3:FLASHES] ABNORMALITY IN TRAVEL SPEED COMPENSATION DATA IS DISPLAYED 923
M-30 SETTING OF PMC DIPSWITCHES 925
M-101 MOM DISPLAY IS NOT GIVEN 926
M-102 MOM DISPLAY IS GOES UT 927
M-103 4-DIGIT ERROR CODE AND ERROR MESSAGE ARE DISPLAYED ON MOM 928
M-104 MOM TIME DISPLAY IS SLOW,WARNING DISPLAY SHOWS DEFECTIVE OPERATION OF CLOCK IC,OR WARNING DISPLAY SHOWS DROP IN BATTERY VOLTAGE 929
M-105 (DROP IN BATTERY VOLTAGE) WARNING IS DISPLAYED 931
TROUBLESHOOTING OF ABS/ASR SYSTEM (OP) 932
TROUBLESHOOTING FLOWCHART 933
FOR MACHINES WITH ABS INSTALLED INDEPENDENTLY 933
FOR MACHINES WITH ABS/ASR INSTALLED 934
METHOD OF DELETING ECU TROUBLE DATA FROM MEMORY 935
PROCEDURE FOR DELETING TROUBLE DATA FROM MEMORY 935
METHOD OF TROUBLESHOOTING USING SELF-DIAGNOSTIC FUNCTION OF ECU 936
INDEX (TROUBLESHOOTING CODE) 937
SYSTEM CHECK SHEET FOR USING SYSTEM CHECKER 939
W-1 WARNING LAMP DOES NOT LIGHT UP 947
I-1 ASR INFORMATION SWITCH DOES NOT GO OUT 948
ASR-1 FAILURE IN ASR CONTROL VALVE (ONLY MACHINES WITH ABS/ASR INSTALLED) 949
ASR-2 950
ABS-1 FAILURE INSIDE ECU 951
ABS-2 FAILURE IN FRONT RIGHT PRESSURE CONTROL VALVE 952
ABS-3 FAILURE IN FRONT LEFT PRESSURE CONTROL VALVE 953
ABS-4 FAILURE IN REAR LEFT PRESSURE CONTROL VALVE 954
ABS-5 FAILURE IN REAR RIGHT PRESSURE CONTROL VALVE 955
ABS-6 FAILURE IN FRONT RIGHT WHEEL SPEED SENSOR 956
ABS-10 ABNORMALITY IN FRONT RIGHT WHEEL SPEED SENSOR OUTPUT 956
ABS-7 FAILURE IN FRONT LEFT WHEEL SPEED SENSOR 957
ABS-11 ABNORMALITY IN FRONT LEFT WHEEL SPEED SENSOR OUTPUT 957
ABS-8 FAILURE IN REAR WHEEL SPEED SENSOR 958
ABS-12 ABNORMALITY IN REAR LEFT WHEEL SPEED SENSOR OUTPUT 958
ABS-9 FAILURE IN REAR RIGHT WHEEL SPEED SENSOR 959
ABS-13 ABNORMALITY IN REAR RIGHT WHEEL SPEED SENSOR OUTPUT 959
ABS-14 FAILURE IN VALVE RELAY (VR2) 960
ABS-15 FAILURE IN VALVE RELAY (VR1) 961
ABS-16 FAILURE IN VALVE RELAY (VR2) 962
ABS-17 FAILURE IN VALVE RELAY (VR1) 963
ABS-18 ABNORMALITY IN POWER SOURCE VOLTAGE 964
TROUBLESHOOTING FOR MAINTENANCE MONITOR SYSTEM 965
MM-1 MAINTENANCE MONITOR DOES NOT WORK 966
a) WHEN NOTHING WORKS 966
b) WHEN CHECK DISPLAY DOES NOT WORK 967
MM-2 WHEN ENGINE IS STOPPED,ENGINE OIL LEVEL DISPLAY FLASHES 968
MM-3 WHEN ENGINE IS STOPPED,TRANSMISSION OIL LEVEL DISPLAY FLASHES 969
MM-4 WHEN ENGINE IS STOPPED,HYDRAULIC OIL LEVEL DISPLAY FLASHES 970
MM-5 WHEN ENGINE IS STOPPED,RETARDER OIL LEVEL DISPLAY FLASHES 970
MM-6 WHEN ENGINE IS STOPPED,BRAKE OIL LEVEL DISPLAY FLASHES 971
MM-7 WHEN ENGINE IS STOPPED,BATTERY ELECTROLYTE LEVEL DISPLAY FLASHES 972
MM-8 AT NEUTRAL,RETARDER WEAR DISPLAY FLASHES 973
MM-9 WHEN ENGINE IS RUNNING,AIR CLEANER CLOGGING DISPLAY FLASHES 974
MM-10 WHEN ENGINE IS RUNNING,FULL-FLOW FILTER CLOGGING DISPLAY FLASHES 975
MM-11 WHEN ENGINE IS RUNNING,TRANSMISSION FILTER CLOGGING DISPLAY FLASHES 976
MM-12 WHEN ENGINE IS RUNNING,HYDRAULIC FILTER CLOGGING DISPLAY FLASHES 977
MM-13 WHEN ENGINE IS RUNNING,RETARDER FILTER CLOGGING DISPLAY FLASHES 978
MM-14 MAINTENANCE TIMER DOES NOT WORK 979
MM-15 MAINTENANCE TIMER IS NOT 0H OR BELOW,BUT MAINTENANCE ITEM LIGHTS UP 979
MM-16 ABNROMALITY IN SWITCH 980
a) CONFIRMATION SWITCH FOR OIL OR FILTER REPLACEMENT TIME DOES NOT WORK 980
b) REPLACEMENT SWITCH,MISOPERATION CANCEL SWITCH DO NOT WORK 980
MM-17 NIGHT LIGHTING DOES NOT LIGHT UP 981
TROUBLESHOOTING FOR AUTOMATIC SPIN REGULATOR (ASR-Ⅱ) SYSTEM (AS MODE) 982
OUTLINE 983
AS-1 FAILURE CODE 0 1 “ABNORMALITY IN POWER SOURCE VOLTAGE” IS DISPLAYED 985
AS-2 FAILURE CODE 1 0 “DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM” IS DISPLAYED 986
AS-3 FAILURE CODE 1 1 “DISCONNECTION IN RR WHEEL SPEED SENSOR” IS DISPLAYED 987
AS-4 FAILURE CODE 1 2 “DISCONNECTION IN RL WHEEL SPEED SENSOR” IS DISPLAYED 988
AS-5 FAILURE CODE 1 3 “DISCONNECTION IN TRANSMISSION OUTPUT SHAFT SPEED SENSOR SYSTEM” IS DISPLAYED 989
AS-6 FAILURE CODE 1 6 “FAILURE IN STEERING ANGLE SENSOR” IS DISPLAYED 990
AS-7 FAILURE CODE 1 7 “FAILURE IN ACCELERATOR SIGNAL SYSTEM” IS DISPLAYED 991
AS-8 FAILURE CODE 4 3 “DISCONNECTION ON ARSC CAUTION LAMP SYSTEM” IS DISPLAYED 992
AS-9 FAILURE CODE 4 5 “DISCONNECTION IN PANEL CAUTION LAMP AND BUZZER SYSTEM” IS DISPLAYED 993
AS-10 FAILURE CODE 5 3 “SHORT CIRCUIT WITH GROUND IN ARSC CAUTION LAMP SYSTEM” IS DISPLAYED 994
AS-11 FAILURE CODE 5 5 “SHORT CIRCUIT WITH GROUND IN PANEL CAUTION LAMP AND BUZZER SYSTEM” IS DISPLAYED 995
AS-12 FAILURE CODE 6 0 “FAILURE IN ENGINE SPEED SENSOR SYSTEM” IS DISPLAYED 996
AS-13 FAILURE CODE 6 1 “FAILURE IN RR WHEEL SPEED SENSOR SYSTEM” IS DISPLAYED 997
AS-14 FAILURE CODE 6 2 “FAILURE IN RL WHEEL SPEED SENSOR SYSTEM” IS DISPLAYED 998
AS-15 FAILURE CODE 8 0 “FAILURE IN PRESSURE CONTROL VALVE (L H ) SYSTEM:PRESSURE CONTROL VALVE (L H )DOES NOT OPEN” IS DISPLAYED 999
AS-16 FAILURE CODE 8 1 “SHORT CIRCUIT WITH CHASSIS GROUND IN PRESSURE CONTROL VALVE (R H ) SYSTEM” IS DISPLAYED 1000
AS-17 FAILURE CODE 8 2 “SHORT CIRCUIT WITH CHASSIS GROUND IN PRESSURE CONTROL VALVE (L H ) SYSTEM” IS DISPLAYED 1001
AS-18 FAILURE CODE 8 3 “DISCONNECTION IN PRESSURE CONTROL VALVE (R H ) SYSTEM” IS DISPLAYED 1002
AS-19 FAILURE CODE 8 4 “DISCONNECTION IN PRESSURE CONTROL VALVE (L H ) SYSTEM” IS DISPLAYED 1003
AS-20 FAILURE CODE 8 5 “FAILURE IN PRESSURE CONTROL VALVE (R H ) SYSTEM:PRESSURE CONTROL VALVE (R H ) DOES NOT CLOSE” IS DISPLAYED 1004
AS-21 FAILURE CODE 8 6 “FAILURE IN PRESSURE CONTROL VALVE (L H ) SYSTEM:PRESSURE CONTROL VALVE (L H ) DOES NOT CLOSE” IS DISPLAYED 1005
AS-22 FAILURE CODE 8 7 “FAILURE IN PRESSURE CONTROL VALVE (R H ) SYSTEM:PRESSURE CONTROL VALVE (R H ) DOES NOT OPEN” IS DISPLAYED 1006
AS-23 FAILURE CODE 8 9 “SHORT CIRCUIT WITH CHASSIS GROUND IN PRESSURE SWITCH VALVE SYSTEM” IS DISPLAYED 1007
AS-24 FAILURE CODE 9 0 “DISCONNECTION IN PRESSURE SWITCH VALVE SYSTEM” IS DISPLAYED 1008
AS-25 FAILURE CODE 9 1 “FAILURE IN PRESSURE SWITCH VALVE SYSTEM:VALVE DOES NOT CLOSE” IS DISPLAYED 1009
AS-26 FAILURE CODE 9 2 “FAILURE IN PRESSURE SWITCH VALVE SYSTEM:VALVE DOES NOT OPEN” IS DISPLAYED 1010
AS-101 NOTHING IS DISPLAYED ON DISPLAY WINDOW OF CONTROLLER 1011
AS-102 FAILURE CODE IS KEPT CLEARED (“–” IS ALWAYS DISPLAYED IN DISPLAY WINDOW OF CONTROLLER) OR CANNOT BE CLEARED 1012
AS-103 ANOTHER CONTROLLER HAS A FAILURE 1013
AS-104 MONITOR LAMP (BUZZER) STAYS ON (OR OFF) 1014
AS-105 DISCONNECTION IN SWITCH SYSTEM OF ASR SYSTEM 1015
AS-106 SHORT CIRCUIT WITH CHASSIS GROUND IN SWITCH SYSTEM OF ASR SYSTEM 1016
AS-107 ASR WORKING LAMP DOES NOT LIGHT UP 1017
AS-108 ASR WORKING LAMP REMAINS LIT 1019
VHMS MACHINE HEALTH DIAGNOSIS SYSTEM (OP) 1021
1 BSAIC PRECAUTIONS 1022
1-1 OPERAION, SAFETY, INSPECITON AND MAINTENANCE OF MACHINE 1022
1-2 OPERATION OF MONITORING SYSTEM 1022
1-3 CONSTANT POWER SUPPLY (BATERY DIRECT POWER SUPPLY) 1022
1-4 PRECAUTIONS AT THE TIME OF TURNING ON THE POWER FOR VHMS 1023
1-5 PRECAUTIONS AT THE TIME OF REPLACING VHMS AND TRANSMISSION CONTROLLER 1023
1-6 OPERATION OF COMMUNICATION (ORB ORB COMMUNICATION) CONTROLLER 1024
2 OVERVIEW 1025
2-1 APPLICABLE MODEL 1025
2-2 BASIC CONFIGURATION (1) AND (2) 1025
2-3 INSTALLATION DRAWING 1028
3 STRUCTURE AND FUNCTION 1030
3-1 VHMS CONTROLLER 1030
3-2 BLOW-BY GAS SENSOR 1030
3-3 ENGINE OIL TEMPERAUTRE SENSOR 1031
3-4 AMPLIFIER FOR EXHAUST GAS TEMPERATURE SENSOR 1032
3-5 COMMUNICATION (ORB ORB COMMUNICATION) CONTROLLER/ANTENNA 1032
4 TROUBLESHOOTING 1034
4-1 TROUBLESHOOTING EQUIPMENT LIST 1034
4-2 CONNECTOR TYPE AND MOUNTING LOCATIONS 1035
4-3 CONNECTOR ARRANGEMENT DIAGRAM 1036
4-4 ELECTRICAL CIRCUIT DIAGRAM 1041
4-5 ERROR CODE LIST 1042
4-6 STANDARD VALUE TABLE FOR ELECTRICAL PARTS 1043
4-7 TROUBLE PHENOMENA LIST 1044
5 DISASSEMBLY AND ASSEMBLY 1056
5-1 REMOVAL AND INTRALLATION OF VHMS CONTROLLER 1056
5-2 REMOVAL AND INSTALLATION OF BLOW-BY GAS SENSOR 1057
5-3 REMOVAL AND INSTALLATION OF BREATHER 1057
5-4 REMOVAL AND INSTALLATION OF ENGINE OIL TEMPERATURE SENSOR 1058
5-5 REMOVAL AND INSTALLATION OF EXHAUST GAS TEMPERATURE SENSOR 1058
5-6 REMOVAL AND INSTALLATION OF EXHAUST GAS TEMPERATURE AMPLIFIER 1059
5-7 REMOVAL AND INSTALLATION OF SNAPSHOT SWITCH 1059
5-8 REMOVAL AND INSTALLATION OF COMMUNICATION (ORB ORG COMMUNICATION) CONTROLER AND ANTENNA 1060
6 SETTING OF VHMS CONTROLLER 1061
6-1 SETTING OF CHMS CONTROLLER 1061
6-2 SETTING ITEM 1061
6-3 SRTTING FLOW (OUTLINE) 1061
6-4 CHECK OF OPERATION AND PERFORMANCE 1062
6-5 DATA COLLECTION 1062
7 DATA RECOVERY AND TRANSMISSION 1063
7-1 DATA RECOVERY 1063
8 INSPECTION AND MAINTEANCE 1068
8-1 INSPECTION TIMING: INSPECTION AND MAINTENANCE TIMING OF MACHINE 1068
8-2 INSPECTION ITEM 1068
9 REPLACEMENT OF PARTS 1069
9-1 WHEN THE CHMS CONTROLLER IS REPLACED 1069
9-2 WHEN COMMUNICATION CONTROLLER IS REPLACED 1069
PROCEDURE Ⅰ FOR INITIAL SETUP OF VHMS 1070
PROCEDURE Ⅱ FOR OPENING ORBCOMM SERVICE 1072
30 DISASSEMBLY AND ASSEMBLY 1076
METHOD OF USING MANUAL 1078
PRECAUTIONS WHEN CARRYING OUT OPERATION 1079
SPECIAL TOOL LIST 1081
STARING MOTOR 1084
REMOVAL AND INSTALLATION 1084
ALTERNATOR 1085
REMOVAL AND INSTALLATION 1085
ENGINE OIL COOLER 1086
REMOVAL AND INSTALLATION 1086
LEFT BANK FUEL INJECTION PUMP 1087
REMOVAL AND INSTALLATION 1087
RIGHT BANK FUEL INJECTION PUMP ASSEMBKY (WITHOUT GOVERNOR) 1088
REMOVAL AND INSTALLATION 1088
AIR COMPRESSOR 1089
REMOVAL AND INSTALLATION 1089
WATER PUMP 1090
REMOVAL AND INSTALLATION 1090
AFTERCOOLER CORE 1091
REMOVAL 1091
INSTALLATION 1092
TURBOCHARGER 1093
REMOVAL AND INSTALLATION 1093
NOZZLE HOLDER 1094
REMOVAL AND INSTALLATION 1094
CYLINDER HEAD 1095
REMOVAL 1095
INSTALLATION 1096
EXHAUST BRAKE 1098
REMOVAL AND INSTALLATION 1098
ENGINE 1099
REMOVAL 1099
INATALLATION 1103
ENGINE FRONT SEAL 1104
REMOVAL AND INSTALLATION 1104
ENGINE REAR SEAL 1107
REMOVAL AND INSTALLATION 1107
RADIATOR TORQUE CONVERTER COOLER 1111
REMOVAL 1111
INSTALLATION 1112
BRAKE COOLER 1113
REMOVAL AND INSTALLATION 1113
OUTPUT SHAFT 1114
REMOVAL AND INSTALLATION 1114
DISASSEMBLY 1116
ASSEMBLY 1117
TORQUE CONVERTER, TRANSMISSION 1119
REMOVAL 1119
INSTALLATION 1121
PROCEDURE FOR CENTERING THE ENGINE ASSEMBLY AND TROQUE CONVERTER, TRANSMISSION ASSEMBLY 1122
TORQUE CONVERTER, CONTROL VALVE 1123
REMOVAL AND INSTALLATION 1123
DISASSEMBLY AND ASSEMBLY 1124
TORQUE CONVERTER AND TRANSMISSION 1125
DISCONNECTION 1125
CONNECTION 1126
TORQUE CONVERTER, PTO 1127
DISASSEMBLY 1127
ASSEMBLY 1133
TRANSMISSION 1139
DISASSEMBLY 1139
ASSEMBLY 1153
ECMV 1170
DISASSEMBLY AND ASSEMBLY 1170
DIFFERENTIAL (FOR STANFARD DIFFERENTIAL) 1172
REMOVAL 1172
INSTALLATION 1173
DISASSEMBLY 1174
ASSEMBLY 1178
DIFFERENTIAL (WITH DIFFERENTIAL LOCK) 1187
REMOVAL 1187
INSTALLATION 1188
DISASSEMBLY 1189
ASSEMBLY 1194
FRONT WHEEL 1204
REMOVAL AND INSTALLATION 1204
REAR WHEEL 1205
REMOVAL 1205
INSTALLATION 1206
FRONT BRAKE CALIPER 1207
REMOVAL AND INSTALLATION 1207
DISASSEMBLY 1208
ASSEMBLY 1209
FRONT BRAKE CALIPER PAD 1211
REMOVAL AND INSTALLATION 1211
FRONT WHEEL HUB 1212
DISASSEMBLY 1212
ASSEMBLY 1214
FINAL DRIVE CARRIER 1217
REMOVAL AND INSTALLATION 1217
DISASSEMBLY AND ASSEMBLY 1218
FINAL DRIVE 1219
DISASSEMBLY 1219
ASSEMBLY 1221
REAR BRAKE 1223
REMOVAL AND INSTALLATION 1223
REAR WHEEL BRAKE 1224
DISASSEMBLY 1224
ASSEMBLY 1225
PARKING BRAKE PAD 1227
REMOVAL 1227
INSTALLATION 1228
PARKING BRAKE CALIPER 1229
REMOVAL AND INSTALLATION 1229
DISASSEMBLY AND ASSEMBLY 1230
FRONT SUSPENDION CYLINDER 1231
REMOVAL AND ISNTALLATION 1231
DISASSEMBLY (STANDARD CYLINDER) 1232
ASSEMBLY (STANDARD CYLINDER) 1233
DISSASSEMBLY (CYLINDER WITH BUFFER RING) 1234
ASSEMBLY (CYLINDER WITH BUFFER RING) 1235
KING PIN 1237
REMOVAL AND INSTALLATION 1237
VARIBLE DAMPING SELECTIOR VALVE 1238
DISASSEMBLY 1238
ASSEMBLY 1239
REAR SUSPENSION CYLINDER 1240
REMOVAL AND INSTALLATION 1240
DISASSEMBLY (STANDARD CYLINDER) 1241
ASSEMBLY (STANDARD CYLINDER) 1242
DISASSEMBLY (CYLINDER WITH BUFFER RING) 1243
ASSEMBLY (CYLINDERWITH BUFFER RING) 1244
AIR GOVERNOR 1245
REMOVAL AND INATALLATION 1245
DISASSEMBLY AND ASSEMBLY 1246
BRAKE VALVE 1247
REMOVAL AND INSTALLATION 1247
DISASSEMBLY 1248
ASSEMBLY 1250
PARKING VRAKE CHAMBER 1252
REMOVAL AND INSTALLATION 1252
DISASSEMBLY 1253
ASSEMBLY 1254
REAR BRAKE VHAMBER 1256
REMOVAL AND INSTALLATION 1256
DISASSEMBLY 1257
ASSEMBLY 1261
FRONT BRAKE CHAMBER 1264
DISASSEMBLY 1264
ASSEMBLY 1266
SLACK ADJUSTER 1268
REMOVAL AND INSTALLATION 1268
DISASSEMBLY AND ASSEMBLY 1269
AIR DRIER (DESICCANT TYPE) 1270
REMOVAL AND INSTALLATION 1270
DISASSEMBLY AND ASSEMBLY 1271
BRAKE COLLING PUMP 1288
REMOVAL AND INSTALLATION 1288
STEERING, HOIST PUMP 1289
REMOVAL AND INSTALLATION 1289
TORQUE CONVERTER, TRANSMISSION PUMP 1290
REMOVAL AND INSTALLATION 1290
EMERGENCY STEERING MOTOR PUMP 1291
REMOVAL AND INSTALLATION 1291
STEERING VALVE 1292
REMOVAL AND INSTALLATION 1292
DISASSEMBLY 1293
ASSEMBLY 1297
BRAKE CONTROL VALVE (BCV) 1304
REMOVAL AND INSTALLATION 1304
DEMAND VALVE 1305
REMOVAL AND INSTALLATION 1305
DISASSEMBLY AND ASSEMBLY 1306
RELIEF VALVE 1307
DISASSEMBLY AND ASSEMBLY 1307
HOIST VALVE 1308
REMOVAL AND INSTALLATION 1308
DISASSEMBLY AND ASSEMBLY 1309
STEERING CYLINDER 1311
REMOVAL AND INSTALATION 1311
DISASSEMBLY 1312
ASSEMBLY 1314
HOIST CYLINDER 1317
REMOVAL AND INSTALLATION 1317
DISASSEMBLY 1318
ASSEMBLY 1319
BODY 1320
REMOVAL 1320
INSTALLATION 1321
CONTROLLER 1322
REMOVAL AND INSTALLATION 1322
AIR CONITIONER COMPRESSOR 1323
REMOVAL AND INSTALLATION 1323
RECEIVER TAKE 1324
REMOVAL AND INSTALLATION 1324
AIR CONDITIONER CONDENSER 1325
REMOVAL AND INSTALLATION 1325
40 MAINTENANCE STANDARD 1326
OUTPUT SHAFT 1327
TURQUE CONVERTER VALVE 1328
TORQUE CONVERTER 1329
TRANSMISSION 1331
ECMV (ELECTRONIC CONTROL MODULATION VALVE) 1336
FRONT AXLE 1337
FRONT AXLE (WITH ABS/ASR) (IF EQUIPPED) 1339
REAR AXLE SUPPORT (HD785-5) 1340
REAR AXLE SUPPORT (HD985-5) 1341
DIFFERENTIAL 1342
FINAL DRIVE (HD785-5) 1344
FINAL DRIVE (HD985-5) 1347
FRONT BRAKE 1349
REAR BRAKE 1350
REAR BRAKE (WITH ABS/ASR) (IF EQUIPPED) 1352
PARKING BRAKE 1354
STEERING LINKAGE 1355
FRONT SUSPENSION CYLINDER 1357
REAR SUSPENSION CYLINDER 1358
PARKING BRAKE CHAMBER 1359
SLACK ADJUSTER 1360
HYDRAULIC PUMP (SAR-160) (FOR TORQUE CONVERTER AND TRANSMISSION) 1361
HYDRAULIC PUMP (SAR4-180+180:FOR STEERING,WORK EQUIPMENT) (SAR4-285+285:FOR BRAKE COOLING) 1362
DEMAND VALVE 1363
CROSS-OVER RELIEF VALVE 1363
HOIST VALVE 1364
STEERING CYLINDER 1365
HOIST CYLINDER 1366
90 OTHERS 1367
ELECTRICAL CIRCUIT DIAGRAM 1368
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH MECHANICAL GOVERNOR) (1/3) 1368
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH MECHANICAL GOVERNOR) (2/3) 1369
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH MECHANICAL GOVERNOR) (3/3) 1370
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH ELECTRONIC GOVERNOR) (1/5) 1371
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH ELECTRONIC GOVERNOR) (2/5) 1372
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH ELECTRONIC GOVERNOR) (3/5) 1373
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH ELECTRONIC GOVERNOR) (4/5) 1374
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH ELECTRONIC GOVERNOR) (5/5) 1375
ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (1/2) 1376
ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (2/2) 1377
ELECTRICAL CONTROL SYSTEM 1378
ELECTRICAL CIRCUIT DIAGRAM 1378
AUTOMATIC SHIFT CONTROL SYSTEM 1379
ELECTRICAL CIRCUIT DIAGRAM (1/2) 1379
ELECTRICAL CIRCUIT DIAGRAM (2/2) 1380
AUTOMATIC SUSPENSION SYSTEM 1381
SYSTEM CIRCUIT DIAGRAM (1/2) 1381
SYSTEM CIRCUIT DIAGRAM (2/2) 1382
PAYLOAD METER (PRINTER TYPE) (OP) 1383
ELECTRICAL CIRCUIT DIAGRAM 1383
PAYLOAD METER Ⅱ(CARD TYPE) (OP) 1384
ELECTRICAL CIRCUIT DIAGRAM 1384
PMC SYSTEM (OP) 1385
ELECTRICAL CIRCUIT DIAGRAM (1/2) 1385
ELECTRICAL CIRCUIT DIAGRAM (2/2) 1387
ASR-Ⅱ SYSTEM (OP) 1387
ELECTRIAL CIRCUIT DIAGRAM 1387
AIR CIRCUIT DIAGRAM 1388
ELECTRICAL CIRCUIT DIAGRAM 1389
ENGINE CONTROL SYSTEM 1389
TRANSMISSION CONTROL SYSTEM 1390
1 ELECTRIC GOVENOR SPECIFICATION 1390
2 MECHANICAL GOVENOR SPECIFICATION 1391
4-4 ELECTRICAL CIRCUIT DIAGRAM 1392

DESCRIPTION:

Komatsu HD785-5 HD985-5 Dump Truck Shop Manual SEBM013917 – PDF DOWNLOAD 

MACHINE MODEL   SERIAL NUMBER
HD785-5                   4001 and up
HD985-5                   1021 and up

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

PREPARATIONS FOR WORK:

S.V 26/12/24