Komatsu HD785-5 HD985-5 Dump Truck Shop Manual SEBM013918 PDF

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Komatsu HD785-5 HD985-5 Dump Truck Shop Manual SEBM013918 – PDF DOWNLOAD

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Komatsu HD785-5 HD985-5 Dump Truck Shop Manual SEBM013918 – PDF DOWNLOAD 

Language : English
Pages : 1464
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu HD785-5 HD985-5 Dump Truck Shop Manual SEBM013918 – PDF DOWNLOAD 

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

COVER 1
CONTENTS 2
LIST OF REVISED PAGES 3
SAFETY 9
SAFETY NOTICE 9
FOREWORD 11
GENERAL 11
HOW TO READ THE SHOP MANUAL 12
HOISTING INSTRUCTIONS 13
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER 14
COATING MATERIALS 16
STANDARD TIGHTENING TORQUE 18
ELECTRIC WIRE CODE 21
CONVERSION TABLE 22
UNITS 28
01 GENERAL 29
GENERAL ASSEMBLY DRAWING 30
SPECIFICATIONS 33
WEIGHT TABLE 36
LIST OF LUBRICANT AND COOLANT 37
10 STRUCTURE AND FUNCTION 39
RADIATOR, TORQUE CONVERTER COOLER 42
BRAKE OIL COOLER 43
POWER TRAIN SKELETON 44
OUTPUT SHAFT (HD785-5) 45
OUTPUT SHAFT (HD985-5) 46
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING 48
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM 49
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT SCHEMATICS 50
TORQUE CONVERTER 52
TORQUE CONVERTER VLAVE 54
LOCKUP SOLENOID VALVE 58
TRANSMISSION 59
TRANSMISSION VALVE 62
ECMV 63
LUBRICATION RELIEF VALVE 68
FRONT AXLE (HD785-5) 69
FRONT AXLE (HD985-5) 70
REAR AXLE (HD785-5) 72
REAR AXLE (HD985-5) 75
DIFFERENTIAL 76
DIFFERENTIAL LOCK CONTROL 78
DIFFERENTIAL LOCK SOLENOID VALVE 80
FINAL DRIVE (HD785-5) 81
FINAL DRIVE (HD985-5) 83
FRONT BRAKE 84
REAR BRAKE 85
PARKING BRAKE 89
WHEELS (HD785-5) 90
WHEELS (HD985-5) 91
AXLE SUPPORT (HD785-5) 92
AXLE SUPPORT (HD985-5) 93
STEERING SYSTEM 94
STEERING WHEEL (HD785-5) 95
STEERING WHEEL (HD985-5) 96
STEERING LINKAGE 98
SUSPENSION SYSTEM 100
SUSPENSION CYLINDER 102
REAR SUSPENSION CYLINDER 105
AIR PIPING 108
AIR CIRCUIT DIAGRAM 110
DESICCANT TYPE AIR DRIER (IF EQUIPPED) 112
AIR GOVERNOR 114
SAFETY VALVE 114
CHECK VALVE 115
DOUBLE CHECK VALVE 115
AUTO DRAIN VALVE 116
HAND BRAKE VALVE 117
BRAKE VALVE 118
EMERGENCY BRAKE CONTROL VALVE 119
PARKING BRAKE CONTROL VALVE 122
PARKING BRAKE PILOT VALVE 123
RELAY VLAVE 124
PARKING BRAKE RELAY VALVE 127
QUICK-RELEASE VALVE 130
PARKING BRAKE CHAMBER 130
RATIO VALVE (FOR FRONT BRAKE) 131
FRONT BRAKE CHAMBER 132
REAR BRAKE CHAMBER 133
SLACK ADJUSTER 136
AIR DRIER (DESICCANT TYPE) (IF EQUIPPED) 137
HYDRAULIC PIPING 140
HYDRALUIC CIRCUIT DIAGRAM 142
DUMP BODY CONTROL 143
HYDRAULIC TANK AND BRAKE COOLING OIL TANK (HD785-5) 144
HYDRAULIC TANK AND BRAKE COOLING OIL TANK (HD985-5) 145
BRAKE COOLING OIL CONTROL VALVE (BCV) 147
STEERING VALVE 148
DEMAND VALVE 152
HOIST VALVE 156
CROSSOVER RELIEF VALVE 158
STEERING CYLINDER 159
HOIST CYLINDER 159
ELECTRICAL CIRCUIT DIAGRAM 161
STOP LAMP SWITCH 164
EXHAUST BRAKE SWITCH 164
TILT SWITCH 164
FRONT BRAKE CUT-OFF VALVE 165
OVERRUN PREVENTION VALVE 166
EXHAUST BRAKE VALVE 166
HORN VALVE 167
PARKING BRAKE SWITCH 167
AIR CONDITIONER 168
PIPING DIAGRAM 168
ELECTRICAL CIRCUIT DIAGRAM 170
REFRIGERANT CIRCUIT DIAGRAM 172
UNIT 173
RECEIVER DRYER 173
CONDENSER 174
COMPRESSOR 174
ENGINE CONTROL SYSTEM 175
SYSTEM DRAWING 175
ELECTRICAL CIRCUIT DIAGRAM 177
FUEL INJECTION PUMP ELECTRIC GOVERNOR 178
HYDRAULIC CIRCUIT DIAGRAM 179
AISS 179
SENSOR, SWITCHES 180
EXHAUST BRAKE 181
SYSTEM DIAGRAM 181
SYSTEM DIAGRAM 182
AUTOMATIC SHIFT CONTROL SYSTEM 184
SYSTEM DIAGRAM 184
ELECTRICAL CIRCUIT DIAGRAM 186
TRANSMISSION CONTROLLER 187
CONNECTOR SIGNALS 188
SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFTING RANGES 189
AUTOMATIC GEAR SHIFTING LINE GRAPH 190
SHIFT LEVER SWITCH 192
SENSORS, SWITCHES 193
TRANSMISSION OIL TEMPERATURE SENSOR 193
FILL SWITCH 194
ACCELERATOR SENSOR 195
SHIFT LIMIT SWITCH 196
MODE SELECTOR SWITCH 196
SELF-DIAGNOSTIC FUNCTION 197
AUTOMATIC EMERGENCY STEERING SYSTEM 198
SYSTEM DIAGRAM 198
ELECTRIC CIRCUIT DIAGRAM 199
FLOW SWITCH 200
RELAY TIMER 202
AUTOMATIC SUSPENSION SYSTEM 203
SYSTEM DIAGRAM 203
STRUCTURE OF SYSTEM 204
SYSTEM CIRCUIT DIAGRAM 205
AUTOMATIC SUSPENSION MODE SELECTION CONTROL 206
SUSPENSION CONTROLLER 207
SENSOR, SWITCHES 208
STEERING ANGLE SENSOR 208
PRESSURE SENSOR 208
SELF-DIAGNOSTIC FUNCTION 209
PAYLOAD METER (PRINTER TYPE) (OP) 210
STRUCTURE OF SYSTEM 210
ELECTRICAL CIRCUIT DIAGRAM 211
PAYLOAD METER BLOCK DIAGRAM 211
PRINCIPLE OF CALCULATION 212
FEATURES OF EQUIPMENT 214
1 PAYLOAD METER 214
2 PRESSURE SENSOR 217
3 CLINOMETER 218
4 LAMP DRIVE RELAY 218
SELF-DIAGNOSTIC FUNCTION 219
PAYLOAD METER Ⅱ (CARD TYPE) (OP) 220
STRUCTURE OF SYSTEM 220
ELECTRICAL CIRCUIT DIAGRAM 221
PAYLOAD METER BLOCK DIAGRAM 221
PRINCIPLE OF MEASUREMENT 222
FEATURE OF EACH DEVICE 223
1 PAYLOAD METER Ⅱ 223
2 PRESSURE SENSOR 251
3 CLINOMETER 252
4 LAMP DRIVE RELAY 252
5 SELF-DIAGNOSTIC FUNCTION 254
MACHINE MONITOR SYSTEM 260
SYSTEM DRAWING 260
MONITOR PANEL DIAGRAM 262
MACHINE MONITOR NORMAL DISPLAY FUNCTONS 263
SELF-DIAGNOSTIC FUNCTION WHEN STARTING SWITCH IS OPERATED 270
TRAVEL SPEED COMPENSATION ROTARY SWITCH 270
SENSORS, SWITCHES 271
ENGINE SPEED SENSOR 271
TRANSMISSION SPEED SENSOR 271
ENGINE OIL PRESSURE 272
ENGINE WATER TEMPERATURE SENSOR 273
RETARDER OIL TEMPERATURE SENSOR 273
TORQUE CONVERTER OIL TEMPERATURE SENSOR 273
AIR PRESSURE SENSOR 273
FUEL LEVEL SENSOR 274
TRANSMISSION OIL FILTER SENSOR 275
RADIATOR WATER LEVEL SENSOR 275
STEERING OIL TEMPERATURE SENSOR 276
BRAKE STROKE SENSOR 276
PMC SYSTEM (MACHINE EQUIPPED WITH ELECTRONIC GOVERNOR) (OP) 277
SYSTEM DIAGRAM 277
ELECTRIC CIRCUIT DIAGRAM 279
POWER TRAIN MANAGEMENT CONTROLLER (PMC) 280
MESSAGE DISPLAY (MOM) 282
SENSOR, SWITCHES 284
ENGINE SPEED SENSOR 284
TRANSMISSION SPEED SENSOR 284
ACCELERATOR SENSOR 285
SUSPENSION PRESSURE SENSOR 286
SENSORS, SWITCHES 287
ENGINE OIL LEVEL SENSOR 287
BRAKE OIL LEVEL SENSOR 287
HYDRAULIC OIL LEVEL SENSOR 288
RETARDER OIL LEVEL SENSOR 288
AIR CLEANER CLOGGING SENSOR 288
RETARDER BRAKE WEAR SENSOR 289
HYDRAULIC FILTER SENSOR 289
RETARDER OIL FILTER SENSOR 289
FULL-FLOW FILTER SENSOR 290
BATTERY ELECTROLYTE LEVEL SENSOR 290
MAINTENANCE MONITOR SYSTEM 291
SYSTEM DIAGRAM 291
MONITOR PANEL 292
MONITOR DISPLAY, FUNCTIONS 293
FUNCTIONS OF SWITCHES 295
SENSORS, SWITCHES 297
ENGINE OIL LEVEL SENSOR 297
RADIATOR WATER LEVEL SENSOR 297
TRANSMISSION OIL LEVEL SENSOR 297
HYDRAULIC OIL LEVEL SENSOR 298
RETARDER OIL LEVEL SENSOR 298
AIR FILTER CLOGGING SENSOR 298
RETARDER BRAKE WEAR SENSOR 299
HYDRAULIC FILTER SENSOR 299
RETARDER OIL FILTER SENSOR 299
TRANSMISSION OIL FILTER SENSOR 299
BATTERY ELECTROLYTE LEVEL SENSOR 300
TORQUE CONVERTER OIL TEMPERATURE SWITCH 300
RETARDER OIL TEMPERATURE SWITCH 300
ABS/ASR SYSTEM 301
SYSTEM CIRCUIT DIAGRAM 301
PRINCIPLE OF OPERATION 303
WHEN ABS IS ACTUATED 304
WHEN ASR IS ACTUATED 305
SYSTEM STRUCTURE DIAGRAM 306
ABS/ASR ELECTRICAL CIRCUIT DIAGRAM 308
ABS/ASR CONTROLLER (ECU) 310
ABS PRESSURE CONTROL VALVE 312
ASR CONTROL VALVE 315
WHEEL SPEED SENSOR 317
RELAY 317
ASR-Ⅱ SYSTEM (IF EUQIPPED) 319
SYSTEM DIAGRAM 319
BASIC OPERATION 320
SYSTEM CONFIGURATION 320
CONTROLLER OF AUTOMATIC SPIN REGULATOR 323
HYDRAULIC TANK PRESSURIZING SYSTEM (HIGH ALTITUDE SPECIFICATION) 324
ELECTRICAL CIRCUIT DIAGRAM OF HYDRAULIC TANK PRESSURIZING SYSTEM 326
AUTO-GREASING SYSTEM 328
ELECTRICAL CIRCUIT DIAGRAM OF AUTO-GREASING 331
AIR AND GREASE CIRCUIT DIAGRAM OF AUTO-GREASING 332
SOLENOID VALVE 333
REGULATOR 333
TIMER 334
20 TESTING AND ADJUSTING 335
STANDARD VALUE TABLE FOR ENGINE BELATED PARTS 336
STANDARD VALUE TABLE FOR CHASSIS 337
STANDARD VALUE TABLE FOR ELECTRICAL PARTS 344
TESTING AND ADJUSTING 359
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING 360
ADJUSTING VALVE CLEARANCE 362
MEASURING COMPRESSION PRESSURE 363
MEASURING BLOWBY PRESSURE 364
MEASURING BOOST PRESSURE 365
MEASURING EXHAUST TRMPERATURE 366
TESTING AND ADJUSTING FUEL INJECTION TIMING 367
ADJUSTING ALTERNATOR BELT TENSION 370
ADJUSTING ENGINE SPEED SENSOR 371
ADJSUTING TRANSMISSION SPEED SENSOR 371
ADJUSTING ACCELERATOR PEDAL 372
TESTING HYDRAULIC PRESSURE OF TORQUE CONVERTER VALVE 373
TESTING ECMV HYDRAULIC PRESSURE 375
TESTING TRANSMISSION LUBRICATION PRESSURE 378
TESTING TORQUE CONVERTER STALL SPEED 379
TESTING BRAKE PRESSURE 381
BLEEDING AIR FROM BRAKE CIRCUIT 382
TESTING WEAR OF FRONT BRAKE PAD 382
TESTING WEAR OF REAR BRAKE DISC 383
ADJUSTING PARKING BRAKE 386
TESTING BRAKE PERFORMANCE 387
TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER (WITH VARIABLE DAMPING FORCE SELECTOR VALVE) 388
TESTING AND ADJUSTING INVERTED TYPE REAR SUSPENSION CYLINDER 392
TESTING AND ADJUSTING SUSPENSION AIR CYLINDER 396
TESTING AND ADJUSTING AIR PRESSURE IN AIR CIRCUIT 397
INSPECTION OF AIR DRIER (DESICCANT TYPE) 398
ADJUSTING HOIST LEVER LINKAGE 400
ADJUSTING BODY POSITIONER 401
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING, HOIST CIRCUIT 402
AIR BLEEDING FROM STEERING CYLINDER 404
ADJUSTING ELECTRONIC MONITOR (SPEEDOMETER,TACHOMETER MODULE) 405
ADJUSTING Q [FUEL INJECTION AMOUNT] WHEN REPLACING ENGINE CONTROLLER 406
SETTING ROTARY SWITCH (MODEL DATA, NETWORK DATA) WHEN REPLACING TRANSMISSION CONTROLLER 407
METHOD OF DELETING DATA FROM ENGINE CONTROLER,TRANSMISSION CONTROLLER AND PMC MEMORY (CONTROL FROM MONITOR PANEL) 408
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM 411
PROCEDURE FOR OPERATING MODULATION CHECKER 417
ADJUSTING HYDRAULIC TANK PRESSURE (HIGH ALTITUDE SPECIFICATION) 422
PERFORMING PM CLINIC USING MANUAL SNAPSHOT (=QUICK PM) 423
PM-CLINIC SERVICE 427
TROUBLESHOOTING 429
POINTS TO REMEMBER WHEN TROUBLESHOOTING 430
SEQUENCE OF EVENTS IN TROUBLESHOOTING 431
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 432
CHECKS BEFORE TROUBLESHOOTING 440
TYPE OF CONNECTOR AND POSITION OF INSTALLATION 442
CONNECTOR PIN ALLOCATION CHART 448
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 454
EXPLANATIONS OF FUNCTIONS (CONTROL MECHANISM) OF ELECTRICAL SYSTEM 480
MONITOR PANEL USER CODES AND SERVICE MODE FUNCTION 488
SELF-DIAGNOSTIC DISPLAY METHOD FOR MONITOR PANEL AND CONTROLLERS 505
TABLE OF SERVICE CODES AND USER CODES 512
METHOD OF USING JUDGEMENT TABLE 522
METHOD OF USING TROUBLESHOOTING CHARTS 523
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (ELECTRONIC GOVERNOR SPECIFICATION G MODE) 525
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE 526
JUDGMENT TABLE FOR TRANSMISSION CONTROLLER, TRANSMISSION RELATED PARTS 534
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE CONTROLLER SYSTEM 538
G-1 C010 [E <–>1 0] ABNORMALITY IN POWER SOURCE 539
G-2 C011 [E <–>1 1] ABNORMALITY IN CONTROLLER 539
G-3 C012 [E <–>1 2] ABNORMALITY IN RACK SENSOR SYSTEM 540
G-4 C013 [E <–>1 3] ABNORMALITY IN RACK SENSOR SYSTEM LEFT BANK 541
G-5 C014 [E <–>1 4] ABNORMALITY IN GOVERNOR SOLENOID SYSTEM RIGHT BANK 542
G-6 C015 [E <–>1 5] ABNORMALITY IN GOVERNOR SOLENOID SYSTEM LEFT BANK 543
G-7 C016 [E <–>1 6] ABNORMALITY IN GOVERNOR CUT RELAY SYSTEM RIGHT BANK 544
G-8 C017 [E <–>1 7] ABNORMALITY IN GOVERNOR CUT RELAY SYSTEM LEFT BANK 545
G-9 C018 [E <–>1 8] ABNORMALITY IN RACK SENSOR POWER SOURCE SYSTEM 546
G-10 C019 [E <–>1 9] ABNORMALITY IN GOVERNOR SERVO SYSTEM RIGHT BANK 547
G-11 C01A [E <–>1 A] ABNORMALITY IN GOVERNOR SERVO SYSTEM LEFT BANK 547
G-12 C01b [E <–>1 b] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM A 548
G-13 C01C [E <–>1 C] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM B 549
G-14 C01d [E <–>1 d] ABNORMALITY IN PRE-STROKE SOLENOID SYSTEM RIGHT BANK 550
G-15 C01E [E <–>1 E] ABNORMALITY IN PRE-STROKE SOLENOID SYSTEM LEFT BANK 551
G-16 C021 [E <–>2 1] MISTAKEN CONNECTION OF CONNECTOR 552
G-17 C022 [E <–>2 2] ENGINE OVERRUN 553
G-18 C023 [E <–>2 3] ENGINE OVERHEATING 553
G-19 C024 [E <–>2 4] DROP IN ENGING OIL PRESSURE 553
G-20 C031 [E <–>3 1] ABNORMALITY IN ACCELERATION SENSOR SYSTEM 554
G-21 C034 [E <–>3 4] ABNORMALITY IN ENGINE COOLANT TEMPERATURE SYSTEM 557
G-22 C036 [E <–>3 6] ABNORMALITY IN ENGINE OIL PRESSURE SENSOR 558
G-23 C055 [E <–>5 5] ABNORMALITY IN NETWORK 559
G-24 C056 [E <–>5 6] ABNORMALITY IN SOLENOID POWER SOURCE SYSTEM RIGHT 560
G-25 C057 [E <–>5 7] ABNORMALITY IN SOLENOID POWER SOURCE SYSTEM LEFT 560
G-26 C058 [E <–>5 8] ABNORMALITY IN BACKUP POWER SOURCE SYSTEM 560
G-27 C059 [E <–>5 9] ABNORMALITY IN BACKUP POWER SOURCE SYSTEM 562
G-28 C0C2 [E <–>C 2] DEFECTIVE MODEL SELECTION DATA 563
G-29 C0C4 [E <–>C 4] ABNORMALITY IN ACCELERATION SENSOR SYSTEM 564
G-30 C0C5 [E <–>C 5] ABNORMALITY IN IDLE VALIDATION 567
G-31 ENGINE DOES NOT START 572
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) 575
METHOD OF USING TROUBLESHOOTING CHART 576
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 580
S-2 ENGINE DOES NOT START 582
a) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED) 582
b) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) 583
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 584
S-4 ENGINE STOPS DURING OPERATIONS 586
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 588
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER) 589
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) 590
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) 591
S-9 OIL BECOMES CONTAMINATED QUICKLY 592
S-10 FUEL CONSUMPTION IS EXCESSIVE 593
S-11 OIL IS IN COOLING, OR WATER SPURTS BACK, OR COOLANT LEVEL GOES DOWN 594
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) 595
S-13 OIL LEVEL RISES 596
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 597
S-15 ABNORMAL NOISE IS MADE 598
S-16 VIBRATION IS EXCESSIVE 600
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A MODE) 601
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 606
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE 608
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER, TRANSMISSION RELATED PARTS 628
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM 630
A-1 ABNORMALITY IN POWER SOURCE SYSTEM 632
a) [u u][OFF]CONTROLLER SELF-DIAGNOSTIC DISPLAY LED DOES NOT LIGHT UP 632
b) bOO1 [E <–>0 1, E C<–>0 1] DROP IN VOLTAGE OF CONTROLLER POWER SOURCE IS DISPLAYED 633
c) bOdA [E <–>d A, E C<–>d A] DROP IN VOLTAGE OF BATTERY DIRECT POWER SOURCE IS DISPLAYED 634
d) bOdb [E <–>d b, E C<–>d b] DROP IN VOLTAGE OF MAIL POWER SOURCE IS DISPLAYED 635
e) bOO2 [E <–>0 2, E C<–>0 2] ABNORMALITAY IN TRANSMISSION CUT RELAY POWER SOURCE IS DISPLAYED 636
A-2 bOO3 [E <–>0 3, E C<–>0 3] ABNORMALITY IN NEUTRAL SAFETY SYSTEM IS DISPLAYED 637
A-3 bOO5 [E <–>0 5, E C<–>0 5] DOUBLE ENGAGEMENT FOR CLUTCH IS DISPLAYED 638
A-4 bOO6 [E <–>0 6, E C<–>0 6] ABNORMALITY IN TRANSMISSION [CUT RELAY] SYSTEM DISPLAYED 639
A-5 bOO8 [E <–>0 8, E C<–>0 8] ABNORMALITY IN REAR BRAKE SOLENOID SYSTEM IS DISPLAYED 640
A-6 bOO9 [E <–>0 9, E C<–>0 9] ABNORMALITY IN EXHAUST BRAKE SOLENOID SYSTEM IS DISPLAYED 641
A-7 642
a) bOC4 [E <–>C 4, E C<–>C 4] SHORT CIRCUIT WITH GROUND IN BCV REAR SOLENOID IS DISPLAYED 642
b) bOC6 [E <–>C 6, E C<–>C 6] SHORT CIRCUIT IN BCV REAR SOLENOID IS DISPLAYED 643
c) bOC8 [E <–>C 8, E C<–>C 8] DISCONNECTION IN BCV REAR SOLENOID IS DISPLAYED 644
A-8 ABNORMALITY IN SPEED SENSOR SYSTEM 645
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) 645
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 647
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 648
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 649
A-9 SPEED SENSOR SYSTEM, CLUTCH SLIPPING 650
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 650
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 651
A-10 ABNORMALITY IN MODEL SELECTION (WIRING HARNESS) IS DISPLAYED 652
a) b014 [E <–>1 4, E C<–>1 4] ABNORMALITY IN MODEL SELECTION (WIRING HARNESS) IS DISPLAYED 652
b) b0A1 [E <–>A 1, E C<–>A 1] ABNORMALITY IN MODEL SELECTION (ROTARY SWITCH) IS DISPLAYED 653
A-11 ABNORMALITY IN SHIFT LEVER SYSTEM 654
a) b007 [E <–>0 7, E C<–>0 7] SHORT CIRCUIT IN SHIFT LEVER ASSEMBLY POWER SOURCE IS DISPLAYED 654
b) b015 [E <–>1 5, E C<–>1 5] SHIFT LEVER POSITION SIGNAL INPUT FOR 2 OR MORE SYSTEM IS DISPLAYED 655
c) b016 [E <–>1 6, E C<–>1 6] SHIFT LEVER POSITION SIGNAL IS NOT INPUT 657
A-12 b017 [E <–>1 7, E C<–>1 7] ABNORMALITY IN ACCELERATOR SIGNAL IS DISPLAYED 659
A-13 b019 [E <–>1 9, E C<–>1 9] ABNORMALITY IN TRANSMISSION OIL TRMPERATURE SENSOR IS DISPLAYED 660
A-14 ABNORMALITY IN PRESSURE CONTROL VALVE SYSTEM 661
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 661
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 663
b-1) INSPECTING FILL SIGNAL SYSTEM 663
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) 664
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) 664
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) 665
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 666
A-17 ABNORMALITY IN SENSOR SYSTEM 668
a) b0A2 [E <–>A 2, E C<–>A 2] ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE SENSOR SYSTEM IS DISPLAYED 668
b) b0A3 [E <–>A 3, E C<–>A 3] ABNORMALITY IN FUEL LEVEL SENSOR SYSTEM IS DISPLAYED 669
c) b0b2 [E <–>b 2, E C<–>b 2] ABNORMALITY IN COOLANT TEMPERATURE SENSOR SYSTEM IS DISPLAYED 670
d) b0b3 [E <–>b 3, E C<–>b 3] ABNORMALITY IN AIR PRESSURE SENSOR SYSTEM IS DISPLAYED 671
e) b0b4 [E <–>b 4, E C<–>b 4] ABNORMALITY IN RETARDER BRAKE OIL TEMPERATURE SENSOR IS DISPLAYED 672
A-18 WARNING DISPLAY 673
a) b0d1 [E <–>d 1, E C<–>d 1] TRANSMISSION FILTER CLOGGED WARNING IS DISPLAYED 673
b) b0d5 [E <–>d 5, E C<–>d 5] TILT WARNING IS DISPLAYED 674
c) b0d6 [E <–>d 6, E C<–>d 6] DROP IN RADIATOR WATER LEVEL WARNING IS DISPLAYED 675
d) b0d7 [E <–>d 7, E C<–>d 7] BATTERY CHARGE LEVEL WARNING IS DISPLAYED 676
e) b0E5 [E <–>E 5, E C<–>E 5] STEERING OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED 677
f) b0F5 [E <–>F 5, E C<–>F 5] DROP IN ENGINE OIL PRESSURE WARNING IS DISPLAYED (MECHANICAL GOVERNOR SPECIFICATION MACHINE) 678
g) b0F6 [E <–>F 6, E C<–>F 6] REAR BRAKE OIL PRESSURE WARNING IS DISPLAYED 679
A-19 b0b7 [E <–>b 7, E C<–>b 7] ABNORMALITY IN ENGINE OIL PRESSURE SYSTEM SENSOR IS DISPLAYED (MECHANICAL GOVERNOR SPECIFITION MACHINE) 680
A-20 b0C1 [E <–>C 1, E C<–>C 1] ABNORMALITY IN CONNECTOR CONNECTION IS DISPLAYED 681
A-21 682
a) b0d2 [E <–>d 2, E C<–>d 2] TORQUE CONVERTER OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED 682
b) b0d3 [E <–>d 3, E C<–>d 3] ENGINE COOLANT TEMPERATURE OVERHEAT WARNING IS DISPLAYED 682
c) b0E9 [E <–>E 9, E C<–>E 9] AIR PRESSURE DROP WARNING IS DISPLAYED 682
d) b0F3 [E <–>F 3, E C<–>F 3] RETARDER BRAKE OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED 682
e) b0d8 [E <–>d 8, E C<–>d 8] ENGINE OVERRUN ACTUATED IS DISPLAYED 683
f) b0d9 [E <–>d 9, E C<–>d 9] ENGINE OVERSHOOT ACTUATED IS DISPLAYED 683
TROUBLESHOOTING OF SUSPENSION CONTROLLER SYSTEM (SP MODE) 685
JUDGMENT TABLE FOR SUSPENSION CONTROLLER, SUSPENSION RELATED PARTS 686
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE 688
ELECTRICAL CIRCUIT DIAGRAM OF SUSPENSION CONTROLLER SYSTEM 692
SP-1 d001 [ALL OFF or E <–>01] ABNORMALITY IN POWER SOURCE IS DISPLAYED 694
SP-2 d011 [E <–>11 IS DISPLAYED] ABNORMALITY IN PRESSURE SENSOR [RIGHT] SYSTEM IS DISPLAYED 695
SP-3 d012 [E <–>12 IS DISPLAYED] ABNORMALITY IN PRESSURE SENSOR [LEFT] SYSTEM IS DISPLAYED 696
SP-4 d015 [E <–>15 IS DISPLAYED] ABNORMALITY IN TRAVEL SPEED SENSOR SYSTEM IS DISPLAYED 697
SP-5 d016 [E <–>16 IS DISPLAYED] ABNORMALITY IN STEERING SENSOR SYSTEM IS DISPLAYED 698
SP-6 d0C2 [E <–>C2 IS DISPLAYED] DEFECTIVE MODEL SELECTION DATA IS DISPLAYED 699
SP-7 d021 [E <–>21 IS DISPLAYED] ABNORMALITY IN SOLENOID [1] SYSTEM IS DISPLAYED 700
SP-8 d022 [E <–>22 IS DISPLAYED] ABNORMALITY IN SOLENOID [2] SYSTEM IS DISPLAYED 701
SP-9 d023 [E <–>23 IS DISPLAYED] ABNORMALITY IN SOLENOID [3] SYSTEM IS DISPLAYED 702
SP-10 d0C1 [E <–>C1 IS DISPLAYED] DISCONNECTION IN NETWROK IS DISPLAYED 703
SP-11 d0C3 [E <–>C3 IS DISPLAYED] DEFECTIVE TRAVEL SPEED COMPENSATION DATA IS DISPLAYED 704
TROUBLESHOOTING OF PAYLOAD METER (PRINTER TYPE) SYSTEM (LP MODE) 705
SERVICE CODES AND SELF-DIAGNOSIS OF PAYLOAD METER (PRINTER TYPE) 706
ELECTRIC CIRCUIT DIAGRAM FOR PAYLOAD METER (PRINTER TYPE) SYSTEM 708
LP-1 NO DISPLAY APPEARS WHEN STARTING SWITCH IS TURNED ON 710
LP-2 CALIBRATION DEMAND (CAL FLASHES) IS SHOWN CONTINUOUSLY AFTER STARTING SWITCH IS TURNED ON 711
LP-3 CALIBRATION CANNOT BE CARRIED OUT 714
LP-4 AFTER STARTING SWITCH IS TURNED ON,ALL EXTERNAL DISPLAY LAMPS DO NOT LIGHT UP 717
LP-5 CONDITION DOES NOT EXIST FOR LAMPS TO LIGHT UP,BUT EXERNAL DISPLAY LAMPS LIGHT UP 719
LP-6 LEVEL OF LIGHTING UP OF EXTERNAL DISPLAY LAMPS IS NOT CORRECT 720
LP-7 ABNORMALITY IN DISPLAY LOGIC 722
LP-8 E01-E04 IS DISPLAYED 727
LP-9 E11-E14 IS DISPLAYED 728
LP-10 E21-E28 IS DISPLAYED BY SENSOR CHECK 729
LP-11 E31 IS DISPLAYED 730
LP-12 E32 IS DISPLAYED 732
LP-13 E41 IS DISPLAYED 734
LP-14 E42 IS DISPLAYED 735
LP-15 PRINTER DOES NOT PRINT ANYTHING (BLANK PAPER COMES OUT) 736
LP-16 PRINTER PRINTS ONLY “NO DATA” 736
LP-17 PRINTER DOES NOT PRINT OUT WHEN PRT SWITCH IS PRESSED 736
LP-18 “PAPE” FLASHES 737
LP-19 TIME IS WRONG 737
LP-20 E33 IS DISPLAYED 737
TROUBLESHOOTING OF PAYLOAD METER Ⅱ (CARD TYPE) SYSTEM (LC MODE) 739
SERVICE CODES AND SELF-DIAGNOSIS OF PAYLOAD METER Ⅱ (CARD TYPE) 740
ELECTRICAL CIRCUIT DIAGRAM FOR PAYLOAD METER Ⅱ (CARD TYPE) SYSTEM 744
LC-1 NO DISPLAY APPEARS WHEN STARTING SWITCH IS TURNED ON 746
LC-2 AFTER STARTING SWITCH IS TURNED ON,ALL EXTERNAL DISPLAY LAMPS DO NOT LIGHT UP 747
LC-3 CONDITION DOES NOT EXIST FOR LAMPS TO LIGHT UP,BUT EXTERNAL DISPLAY LAMPS LIGHT UP 748
LC-4 LEVEL OF LIGHTING UP OF EXTERNAL DISPLAY LAMPS IS NOT CORRECT 749
LC-5 CYCLE DATA IS NOT RECOREDE,ON/OFF DATA IS NOT RECORDED:BATTERY CHARGE SIGNAL SYSTEM:ENGINE IS NOT STARTED IS DETECTED 751
LC-6 CALIBRATION CANNOT BE CARRIED OUT,TIME DISPLAY DOES NOT MATCH CONDITIONS:SHIFT LEVER N POSITION SIGNAL SYSTEM 752
LC-7 ABNORMALITY IN DISPLAY LOGIC 753
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 755
LC-9 F-09 IS DISPLAYED:DROP IN VOLTAGE OF BACK-UP BATTERY BUILT INTO PAYLOAD METER 756
LC-10 FULL DISPLAY APPEARS 756
LC-11 F-20 IS DISPLAYED:SENSOR POWER SOURCE VOLTAGE SYSTEM 757
LC-12 F-21 – F-24 IS DISPLAYED:DISCONNECTION,SHORT CIRCUIT WITH GROUND SUSPENSION PRESSURE SENSOR SYSTEM 758
LC-13 F-25 – F-28 IS DISPLAYED:SHORT CIRCUIT IN SUSPENSION PRESSURE SENSOR SYSTEM POWER SOURCE 760
LC-14 F CAL IS DISPLAYED:CALIBRATION NOT CARRIED OUT,DAMAGED DATA INSIDE PAYLOAD METER 761
LC-15 F-41 – F-45 IS DISPLAYED:SHORT CIRCUIT IN EXTERNAL DISPLAY LAMP SYSTEM POWER SOURCE 762
LC-16 L-BAD IS DISPLAYED:CYCLE DATA SAVED WHEN MACHINE WAS SWAYING 764
LC-17 MACHINE IS NOT LOADING BUT EXTERNAL DISPLAY LAMPS GIVE LOAD ESTIMATE DISPLAY AFTER LOADING,DISPLAY SWITCHES TO TIME DISPLAY BEFORE TRAVELING 160m 765
LC-18 F-31 IS DISPLAYED:DISCONNECTION,SHORT CIRCUIT WITH GROUND IN CLINOMETER SYSTEM 766
LC-19 F-32 IS DISPLAYED:SHORT CIRCUIT WITH CLINOMETER SYSTEM POWER SOURCE 767
LC-20 F-18 IS DISPLAYED:DISCONNECTION IN BATTERY CHARGE SIGNAL 768
LC-21 F-93 – 99 ARE DISPLAYED:ABNORMALITY IN NETWORK (WHEN PMC IS INSTALLED) 769
LC-22 F-71,73,80,91,92 ARE DISPLAYED:(WHEN PMC,TALKS ARE INSTALLED) 770
TROUBLESHOOTING OF ARSC [AUTOMATIC RETARDER SPEED CONTROLLER] SYSTEM (R MODE) 771
OUTLINE 772
ELECTRICAL CIRCUIT DIAGRAM FOR ARSC (AUTOMATIC RETARDER SPEED CONTROLLER) SYSTEM 776
R-1 0 1 (ABNORMALITY IN POWER SOURCE VOLTAGE) IS DISPLAYED 778
R-2 1 0 (DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED 779
R-3 1 3 (DISCONNECTION IN TRANSMISSION OUTPUT SHAFT SPEED SENSOR SYSTEM) IS DISPLAYED 780
R-4 1 5 (FAILURE IN RETARDER OIL TEMPERATURE SENSOR SYSTEM) IS DISPLAYED 781
R-5 1 7 (FAILURE IN ACCELERATOR SIGNAL SYSTEM) IS DISPLAYED 782
R-6 1 8 (FAILURE IN SUSPENSION PRESSURE SENSOR “LEFT” SYSTEM) IS DISPLAYED 783
R-7 1 9 (FAILURE IN SUSPENSION PRESSURE SENSOR “RIGHT” SYSTEM) IS DISPLAYED 784
R-8 4 2 (DISCONNECTION IN EXHAUST BRAKE SELECTOR SIGNAL SYSTEM) IS DISPLAYED 785
R-9 4 3 (DISCONNECTION IN ARSC CAUTION LAMP SYSTEM) IS DISPLAYED 786
R-10 4 4 (DISCONNECTION IN READY LAMP SYSTEM) IS DISPLAYED 787
R-11 4 5 (DISCONNECTION IN PANEL CAUTION AND BUZZER SYSTEM) IS DISPLAYED 788
R-12 5 2 (SHORT CIRCUIT WITH GROUND EXHAUST BRAKE SELECTOR SIGNAL OUTPUT SYSTEM) IS DISPLAYED 789
R-13 5 3 (SHORT CIRCUIT WITH GROUND IN ARSC CAUTION LAMP SYSTEM) IS DISPLAYED 790
R-14 5 4 (SHORT CIRCUIT WITH GROUND IN READY OUTPUT CIRCUIT SYSTEM) IS DISPLAYED 791
R-15 5 5 (SHORT CIRCUIT WITH GROUND IN PANEL CAUTION LAMP AND BUZZER OUTPUT SYSTEM) IS DISPLAYED 792
R-16 6 0 (FAILURE IN ENGINE SPEED SYSTEM) IS DISPLAYED 793
R-17 7 0 (DISCONNECTION IN TRAVEL SPEED DISPLAY UP OUTPUT SYSTEM) IS DISPLAYED 794
R-18 7 1 (DISCONNECTION IN TRAVEL SPEED DISPLAY DOWN OUTPUT SYSTEM) IS DISPLAYED 795
R-19 7 2 (DISCONNECTION IN TRAVEL SPEED DISPLAY CLEAR OUTPUT SYSTEM) IS DISPLAYED 796
R-20 7 3 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY UP OUTPUT SYSTEM) IS DISPLAYED 797
R-21 7 4 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY DOWN OUTPUT SYSTEM) IS DISPLAYED 798
R-22 7 5 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY CLEAR OUTPUT SYSTEM) IS DISPLAYED 799
R-23 8 1 (SHORT CIRCUIT WITH GROUND IN PRESSURE CONTROL VALVE SYSTEM) IS DISPLAYED 800
R-24 8 3 (DISCONNECTION IN PRESSURE CONTROL VALVE SYSTEM) IS DISPLAYED 801
R-25 8 5 (FAILURE IN PRESSURE CONTROL VALVE (PRESSURE CONTROL VALVE REMAINS OPEN)) IS DISPLAYED 802
R-26 8 7 (FAILURE IN PRESSURE CONTROL VALVE (PRESSURE CONTROL VALVE DOES NOT OPEN)) IS DISPLAYED 803
R-27 8 9 (SHORT CIRCUIT WITH GROUND IN PRESSURE SWITCH VALVE SYSTEM) IS DISPLAYED 804
R-28 9 0 (DISCONNECTION IN PRESSURE SWITCH VALVE SYSTEM) IS DISPLAYED 805
R-29 9 1 (FAILURE IN PRESSURE SWITCH VALVE SYSTEM (REMAINS OPEN)) IS DISPLAYED 806
R-30 9 2 (FAILURE IN PRESSURE SWITCH VALVE SYSTEM (DOES NOT OPEN)) IS DISPLAYED 807
R-31 9 3 (DISCONNECTION IN SYSTEM SWITCH SYSTEM) IS DISPLAYED 808
R-32 9 4 (SHORT CIRCUIT WITH GROUND IN SYSTEM SWITCH SYSTEM) IS DISPLAYED 809
R-33 9 5 (DISCONNECTION,SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED SETTING SWITCH SYSTEM) IS DISPLAYED 810
R-101 SET SPEED CANNOT BE SET 811
R-102 FAILURE CODE IS ALWAYS CLEARED (CONTROLLER DISPLAY WINDOW ALWAYS SHOWS “–“) OR FAILURE CODE CANNOT BE CLEARED 814
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) 815
R-104 ABNORMALITY APPEARS IN OTHER CONTROLLER 815
R-105 WHEN TRAVELING DOWNHILL,EVEN WHEN SET SPEED IS EXCEEDED,NO CONTROL IS CARRIED OUT 816
R-106 MONITOR LAMP (BUZZER) STAYS ON (OR OFF) 817
R-107 READY LAMP DOES NOT LIGHT UP (OR STAYS LIGHTED UP) 818
R-108 EXHAUST BRAKE DOES NOT WORK PROPERLY 820
R-109 THERE IS DIFFERENCE BETWEEN TRAVEL SPEED ROD VALUE AND ACTUAL MACHINE VALUE 822
R-110 RETARDER LAMP DOES NOT LIGHT UP,OR STAYS LIGHTED UP 825
R-111 TRAVEL SPEED DISPLAY ALWAYS GIVES DISPLAY (OR DOES NOT GIVE ANY DISPLAY) 826
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) 827
H-1 MACHINE DOES NOT START 828
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY 830
H-3 LOCK-UP CLUTCH CANNOT BE DISENGAGED 830
H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING 831
H-5 TRANSMISSION DOES NOT SHIFT UP 831
H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING 832
H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR 836
H-8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH 838
H-9 TORQUE CONVERTER OIL PRESSURE IS LOW 839
H-10 FRONT BRAKE IS INEFFECTIVE,OR EFFECTIVE ONLY ON ONE SIDE 840
H-11 REAR BRAKE IS INEFFECTIVE,OR EFFECTIVE ONLY ON ONE SIDE 841
H-12 STEERING WHEEL IS HEAVY 842
H-13 STEERING WHEEL DOES NOT WORK 843
H-14 STEERING WHEEL VIBRATES 843
H-15 HOIST CYLINDER LACKS LIFTING FORCE (LIFTING SPEED) 844
H-16 HOIST CYLINDER DOES NOT WORK 845
H-17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY 846
H-18 AIR PRESSURE DOES NOT RISE 847
TROUBLESHOOTING OF MONITOR PANEL SYSTEM (P MODE) 849
METHOD OF SELF-DIAGNOSTIC DISPLAY FOR MONITOR PANEL AND CONTROLLERS 851
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE (MONITOR PANEL SYSTEM) 852
ELECTRICAL CIRCUIT DIAGRAM FOR MONITOR PANEL SYSTEM 856
P-1 CHECK PATTERN FOR WIRING HARNESSES BETWEEN MODULES 858
P-2 NOTHING ON MONITOR PANEL WORKS 862
P-3 LH,RH MODULE AND FUEL GAUGE DO NOT WORK 863
P-4 LH,RH MODULE AND FUEL GAUGE DO NOT WORK 864
P-5 RH MODULE DOES NOT WORK 865
P-6 LH MODULE DOES NOT WORK 866
P-7 TRAVEL CALCULATOR DOES NOT WORK 867
P-8 SERVICE METER DISPLAY DOES NOT WORK CORRECTLY 868
P-9 CENTRAL WARNING LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS FAILURE CODE [A002] 869
P-10 CENTRAL WARNING LAMP STAYS LIGHTED UP 870
P-11 ALARM BUZZER DOES NOT WORK,OR MONITOR PANEL DETECTS FAILURE CODE [A003] 871
P-12 ALARM BUZZER CONTINUES TO SOUND 872
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] 873
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] 874
P-15 GAUGE DISPLAYS ARE ABNORMAL (NOTHING IS DISPLAYED,OR DISPLAY DOES NOT CHANGE) 875
P-16 COOLANT LEVEL DROP CAUTION LAMPS DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001] 876
P-17 COOLANT LEVEL DROP CAUTION LAMP STAYS LIGHTED UP 877
P-18 EMERGENCY STEERING PILOT LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SEVICE CODE [A001] 878
P-19 EMERGENCY STEERING PILOT LAMP STAYS LIGHTED UP 879
P-20 ENGINE OIL PRESSURE DROP CAUTION LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001] 880
P-21 ENGINE OIL PRESSURE DROP CAUTION LAMP STAYS LIGHTED UP 881
P-22 EXHAUST BRAKE PILOT LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001] 882
P-23 EXHAUST BRAKE PILOT LAMP STAYS LIGHTED UP 883
P-24 CHARGING CIRCUIT ABNORMALITY CAUTION LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001] 884
P-25 CHARGING CIRCUIT ABNORMALITY CAUTION LAMP STAYS LIGHTED UP 885
P-26 TRANSMISSION FILTER CLOGGING CAUTION LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001] 886
P-27 TRANSMISSION FILTER CLOGGING CAUTION LAMP STAYS LIGHTED UP 887
P-28 BRAKE STROKE CAUTION LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001] 888
P-29 BRAKE STROKE CAUTION LAMP STAYS LIGHTED UP 889
P-30 PREHEATING SWITCH PILOT LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001] 890
P-31 PREHEATING SWITCH PILOT LAMP STAYS LIGHTED UP 891
P-32 TILT WARNING LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001] 892
P-33 TILT WARNING LAMP STAYS LIGHTED UP 893
P-34 BODY FLOAT (EXCEPT FLOAT) PILOT LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001] 894
P-35 BODY FLOAT (EXCEPT FLOAT) PILOT LAMP STAYS LIGHTED UP 895
P-36 REAR BRAKE PILOT LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001] 896
P-37 REAR BRAKE PILOT LAMP STAYS LIGHTED UP 897
P-38 PARKING BRAKE PILOT LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001] 898
P-39 PARKING BRAKE PILOT LAMP STAYS LIGHTED UP 899
P-40 MAINTENANCE CAUTION LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001] 900
P-41 MAINTENANCE CAUTION LAMP STAYS LIGHTED UP 901
P-42 STEERING OIL TEMPERATURE CAUTION LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001] 902
P-43 STEERING OIL TEMPERATURE CAUTION LAMP STAYS LIGHTED UP 903
P-44 DIFFERENTIAL LOCK PILOT LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001] 904
P-45 DIFFERENTIAL LOCK PILOT LAMP STAYS LIGHTED UP 905
P-46 HIGH BEAM DISPLAY DOES NOT LIGHT UP 906
P-47 TURN SIGNAL LAMP (RIGHT) DOES NOT LIGHT UP 908
P-48 TURN SIGNAL LAMP (LEFT) DOES NOT LIGHT UP 909
P-49 LAMP CHECK SWITCH DOES NOT WORK 910
P-50 AISS SWITCH DOES NOT WORK 911
P-51 EXHAUST BRAKE SWITCH DOES NOT WORK 912
P-52 MODE CHANGE SWITCH (1) DOES NOT WORK 913
P-53 MODE CHANGE SWITCH (2) DOES NOT WORK 914
P-54 KPH/MPH SPEEDOMETER UNIT SELECTOR DOES NOT WORK 915
P-55 DEFECTIVE OPERATION OF ALL SWITCH INPUTS 916
P-56 MONITOR PANEL DETECTS SERVICE CODES [A014] OR [A019] 917
P-57 MONITOR PANEL DETECTS SERVICE CODE [A015] 918
P-58 MONITOR PANEL DETECTS SERVICE CODE [A011] 919
P-59 MONITOR PANEL DETECTS SERVICE CODE [A012] 919
P-60 MONITOR PANEL DETECTS SERVICE CODE [A000] 919
TROUBLESHOOTING OF PMC SYSTEM (M MODE) 921
PMC RELATED ELECTRIC CIRCUIT DIAGRAM 924
M-1 PMC DOES NOT WORK 926
M-2 E002 [0 2:FLASHES] FAILURE IN NV RAM DATA IS DISPLAYED 927
M-3 E002 [0 2:FLASHES] DROP IN BATTERY DIRECT POWER SOURCE VOLTAGE IS DISPLAYED 928
M-4 E003 [0 3:FLASHES] ABNROMALITY IN CONNECTOR CONNECTION IS DISPLAYED 930
M-5 E011 [1 1:FLASHES] DISCONNECTION IN GSP COMMUNICATIONS IS DISPLAYED 931
M-5 E012 [1 2:FLASHES] ABNORMALITY IN GSP COMMUNICATIONS IS DISPLAYED 931
M-6 E013 [1 3:FLASHES] DISCONNECTION IN MOM COMMUNICATIONS IS DISPLAYED 932
M-6 E014 [1 4:FLASHES] ABNORMALITY IN MOM COMMUNICATIONS IS DISPLAYED 932
M-7 E015 [1 5:FLASHES] DISCONNECTION IN TMS COMMUNICATIONS IS DISPLAYED 933
M-7 E016 [1 6:FLASHES] ABNORMALITY IN TMS COMMUNICATIONS IS DISPLAYED 933
M-8 E017 [1 7:FLASHES] DISCONNECTION IN CENSE COMMUNICATIONS IS DISPLAYED 933
M-8 E018 [1 8:FLASHES] ABNORMALITY IN CENSE COMMUNICATIONS IS DISPLAYED 933
M-9 E026 [2 6:FLASHES] COMMUNICATIONS ABNORMALITY 1 IS DISPLAYED 934
M-9 E027 [2 7:FLASHES] COMMUNICATIONS ABNORMALITY 2 IS DISPLAYED 934
M-9 E028 [2 8:FLASHES] COMMUNICATIONS ABNORMALITY 3 IS DISPLAYED 934
M-9 E029 [2 9:FLASHES] COMMUNICATIONS ABNORMALITY 4 IS DISPLAYED 934
M-9 E02A [2 A:FLASHES] COMMUNICATIONS ABNORMALITY 5 IS DISPLAYED 934
M-10 E035 [3 5:FLASHES] ABNORMALITY IN IDLE VALIDATION IS DISPLAYED 936
M-11 E041 [4 1:FLASHES] SHORT CIRCUIT WITH GROUND/DISCONNECTION IN SUSPENSION PRESSURE SENSOR (RIGHT) SYSTEM IS DISPLAYED 938
M-11 E042 [4 2:FLASHES] SHORT CIRCUIT WITH GROUND/DISCONNECTION IN SUSPENSION PRESSURE SENSOR (LEFT) SYSTEM IS DISPLAYED 938
M-11 E043 [4 3:FLASHES] SHORT CIRCUIT IN SUSPENSION PRESSURE SENSOR (RIGHT) SYSTEM IS DISPLAYED 938
M-11 E044 [4 4:FLASHES] SHORT CIRCUIT IN SUSPENSION PRESSURE SENSOR (LEFT) SYSTEM IS DISPLAYED 938
M-12 E054 [5 4:FLASHES] DISCONNECTION IN ACCELERATOR SIGNAL SYSTEM IS DISPLAYED 939
M-13 E055 [5 5:FLASHES] SHORT CIRCUIT IN ACCELERATOR CELL SIGNAL SYSTEM IS DISPLAYED 940
M-14 E056 [5 6:FLASHES] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED 941
M-15 E057 [5 7:FLASHES] ABNORMALITY IN INPUT SHAFT SPEED SENSOR SYSTEM IS DISPLAYED 942
M-16 E058 [5 8:FLASHES] ABNORMALITY IN TRAVEL SPEED SENSOR (TRANSMISSION OUTPUT SHAFT SPEED SENSOR) IS DISPLAYED 943
M-17 E0A1 [A 1:FLASHES] WHEN ENGINE IS NOT RUNNING,DROP IN BRAKE OIL LEVEL IS DISPLAYED 944
M-18 E0A2 [A 2:FLASHES] WHEN ENGINE IS NOT RUNNING,DROP IN RETARDER OIL LEVEL IS DISPLAYED 945
M-19 E0A3 [A 3:FLASHES] WHEN ENGINE IS NOT RUNNING,DROP IN HYDRAULIC OIL LEVEL IS DISPLAYED 946
M-20 E0A6 [A 6:FLASHES] WHEN ENGINE IS RUNNING,RETARDER FILTER CLOGGED IS DISPLAYED 947
M-21 E0A7 [A 7:FLASHES] WHEN ENGINE IS RUNNING,FULL-FLOW FILTER CLOGGED IS DISPLAYED 948
M-22 E0A8 [A 8:FLASHES] WHEN ENGINE IS RUNNING,HYDRAULIC FILTER CLOGGED IS DISPLAYED 949
M-23 E0b2 [b 2:FLASHES] AT NEUTRAL,RIHGT RETARDER BRAKE DISC WEAR IS DISPLAYED 950
M-24 E0b3 [b 3:FLASHES] AT NEUTRAL,LEFT RETARDER BRAKE DISC WEAR IS DISPLAYED 951
M-25 E0b4 [b 4:FLASHES] WHEN ENGINE IS NOT RUNNING,DROP IN BATTERY ELECTROLYTE LEVEL IS DISPLAYED 952
M-26 E0b5 [b 5:FLASHES] WHEN ENGINE IS NOT RUNNING, DROP IN ENGINE OIL LEVEL IS DISPLAYED 953
M-27 E0b6 [b 6:FLASHES] WHEN ENGINE IS RUNNING,AIR CLEANER CLOGGED IS DISPLAYED 954
M-28 E0C1 [C 1:FLASHES] ABNORMALITY IN NETWORK SYSTEM IS DISPLAYED 955
M-28 E0C2 [C 2:FLASHES] ABNORMALITY IN MODEL SELECTION DATA IS DISPLAYED 955
M-29 E0C3 [C 3:FLASHES] ABNORMALITY IN TRAVEL SPEED COMPENSATION DATA IS DISPLAYED 957
M-30 SETTING OF PMC DIPSWITCHES 959
M-101 MOM DISPLAY IS NOT GIVEN 960
M-102 MOM DISPLAY IS GOES UT 961
M-103 4-DIGIT ERROR CODE AND ERROR MESSAGE ARE DISPLAYED ON MOM 962
M-104 MOM TIME DISPLAY IS SLOW,WARNING DISPLAY SHOWS DEFECTIVE OPERATION OF CLOCK IC,OR WARNING DISPLAY SHOWS DROP IN BATTERY VOLTAGE 963
M-105 (DROP IN BATTERY VOLTAGE) WARNING IS DISPLAYED 965
TROUBLESHOOTING OF ABS/ASR SYSTEM (OP) 967
TROUBLESHOOTING FLOWCHART 968
FOR MACHINES WITH ABS INSTALLED INDEPENDENTLY 968
FOR MACHINES WITH ABS/ASR INSTALLED 969
METHOD OF DELETING ECU TROUBLE DATA FROM MEMORY 970
PROCEDURE FOR DELETING TROUBLE DATA FROM MEMORY 970
METHOD OF TROUBLESHOOTING USING SELF-DIAGNOSTIC FUNCTION OF ECU 971
INDEX (TROUBLESHOOTING CODE) 972
SYSTEM CHECK SHEET FOR USING SYSTEM CHECKER 974
W-1 WARNING LAMP DOES NOT LIGHT UP 982
I-1 ASR INFORMATION SWITCH DOES NOT GO OUT 983
ASR-1 FAILURE IN ASR CONTROL VALVE (ONLY MACHINES WITH ABS/ASR INSTALLED) 984
ASR-2 985
ABS-1 FAILURE INSIDE ECU 986
ABS-2 FAILURE IN FRONT RIGHT PRESSURE CONTROL VALVE 987
ABS-3 FAILURE IN FRONT LEFT PRESSURE CONTROL VALVE 988
ABS-4 FAILURE IN REAR LEFT PRESSURE CONTROL VALVE 989
ABS-5 FAILURE IN REAR RIGHT PRESSURE CONTROL VALVE 990
ABS-6 FAILURE IN FRONT RIGHT WHEEL SPEED SENSOR 991
ABS-10 ABNORMALITY IN FRONT RIGHT WHEEL SPEED SENSOR OUTPUT 991
ABS-7 FAILURE IN FRONT LEFT WHEEL SPEED SENSOR 992
ABS-11 ABNORMALITY IN FRONT LEFT WHEEL SPEED SENSOR OUTPUT 992
ABS-8 FAILURE IN REAR WHEEL SPEED SENSOR 993
ABS-12 ABNORMALITY IN REAR LEFT WHEEL SPEED SENSOR OUTPUT 993
ABS-9 FAILURE IN REAR RIGHT WHEEL SPEED SENSOR 994
ABS-13 ABNORMALITY IN REAR RIGHT WHEEL SPEED SENSOR OUTPUT 994
ABS-14 FAILURE IN VALVE RELAY (VR2) 995
ABS-15 FAILURE IN VALVE RELAY (VR1) 996
ABS-16 FAILURE IN VALVE RELAY (VR2) 997
ABS-17 FAILURE IN VALVE RELAY (VR1) 998
ABS-18 ABNORMALITY IN POWER SOURCE VOLTAGE 999
TROUBLESHOOTING FOR MAINTENANCE MONITOR SYSTEM 1001
MM-1 MAINTENANCE MONITOR DOES NOT WORK 1002
a) WHEN NOTHING WORKS 1002
b) WHEN CHECK DISPLAY DOES NOT WORK 1003
MM-2 WHEN ENGINE IS STOPPED,ENGINE OIL LEVEL DISPLAY FLASHES 1004
MM-3 WHEN ENGINE IS STOPPED,TRANSMISSION OIL LEVEL DISPLAY FLASHES 1005
MM-4 WHEN ENGINE IS STOPPED,HYDRAULIC OIL LEVEL DISPLAY FLASHES 1006
MM-5 WHEN ENGINE IS STOPPED,RETARDER OIL LEVEL DISPLAY FLASHES 1006
MM-6 WHEN ENGINE IS STOPPED,BRAKE OIL LEVEL DISPLAY FLASHES 1007
MM-7 WHEN ENGINE IS STOPPED,BATTERY ELECTROLYTE LEVEL DISPLAY FLASHES 1008
MM-8 AT NEUTRAL,RETARDER WEAR DISPLAY FLASHES 1009
MM-9 WHEN ENGINE IS RUNNING,AIR CLEANER CLOGGING DISPLAY FLASHES 1010
MM-10 WHEN ENGINE IS RUNNING,FULL-FLOW FILTER CLOGGING DISPLAY FLASHES 1011
MM-11 WHEN ENGINE IS RUNNING,TRANSMISSION FILTER CLOGGING DISPLAY FLASHES 1012
MM-12 WHEN ENGINE IS RUNNING,HYDRAULIC FILTER CLOGGING DISPLAY FLASHES 1013
MM-13 WHEN ENGINE IS RUNNING,RETARDER FILTER CLOGGING DISPLAY FLASHES 1014
MM-14 MAINTENANCE TIMER DOES NOT WORK 1015
MM-15 MAINTENANCE TIMER IS NOT 0H OR BELOW,BUT MAINTENANCE ITEM LIGHTS UP 1015
MM-16 ABNROMALITY IN SWITCH 1016
a) CONFIRMATION SWITCH FOR OIL OR FILTER REPLACEMENT TIME DOES NOT WORK 1016
b) REPLACEMENT SWITCH,MISOPERATION CANCEL SWITCH DO NOT WORK 1016
MM-17 NIGHT LIGHTING DOES NOT LIGHT UP 1017
TROUBLESHOOTING FOR AUTOMATIC SPIN REGULATOR (ASR-Ⅱ) SYSTEM (AS MODE) 1019
OUTLINE 1020
AS-1 FAILURE CODE 0 1 “ABNORMALITY IN POWER SOURCE VOLTAGE” IS DISPLAYED 1022
AS-2 FAILURE CODE 1 0 “DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM” IS DISPLAYED 1023
AS-3 FAILURE CODE 1 1 “DISCONNECTION IN RR WHEEL SPEED SENSOR” IS DISPLAYED 1024
AS-4 FAILURE CODE 1 2 “DISCONNECTION IN RL WHEEL SPEED SENSOR” IS DISPLAYED 1025
AS-5 FAILURE CODE 1 3 “DISCONNECTION IN TRANSMISSION OUTPUT SHAFT SPEED SENSOR SYSTEM” IS DISPLAYED 1026
AS-6 FAILURE CODE 1 6 “FAILURE IN STEERING ANGLE SENSOR” IS DISPLAYED 1027
AS-7 FAILURE CODE 1 7 “FAILURE IN ACCELERATOR SIGNAL SYSTEM” IS DISPLAYED 1028
AS-8 FAILURE CODE 4 3 “DISCONNECTION ON ARSC CAUTION LAMP SYSTEM” IS DISPLAYED 1029
AS-9 FAILURE CODE 4 5 “DISCONNECTION IN PANEL CAUTION LAMP AND BUZZER SYSTEM” IS DISPLAYED 1030
AS-10 FAILURE CODE 5 3 “SHORT CIRCUIT WITH GROUND IN ARSC CAUTION LAMP SYSTEM” IS DISPLAYED 1031
AS-11 FAILURE CODE 5 5 “SHORT CIRCUIT WITH GROUND IN PANEL CAUTION LAMP AND BUZZER SYSTEM” IS DISPLAYED 1032
AS-12 FAILURE CODE 6 0 “FAILURE IN ENGINE SPEED SENSOR SYSTEM” IS DISPLAYED 1033
AS-13 FAILURE CODE 6 1 “FAILURE IN RR WHEEL SPEED SENSOR SYSTEM” IS DISPLAYED 1034
AS-14 FAILURE CODE 6 2 “FAILURE IN RL WHEEL SPEED SENSOR SYSTEM” IS DISPLAYED 1035
AS-15 FAILURE CODE 8 0 “FAILURE IN PRESSURE CONTROL VALVE (L H ) SYSTEM:PRESSURE CONTROL VALVE (L H )DOES NOT OPEN” IS DISPLAYED 1036
AS-16 FAILURE CODE 8 1 “SHORT CIRCUIT WITH CHASSIS GROUND IN PRESSURE CONTROL VALVE (R H ) SYSTEM” IS DISPLAYED 1037
AS-17 FAILURE CODE 8 2 “SHORT CIRCUIT WITH CHASSIS GROUND IN PRESSURE CONTROL VALVE (L H ) SYSTEM” IS DISPLAYED 1038
AS-18 FAILURE CODE 8 3 “DISCONNECTION IN PRESSURE CONTROL VALVE (R H ) SYSTEM” IS DISPLAYED 1039
AS-19 FAILURE CODE 8 4 “DISCONNECTION IN PRESSURE CONTROL VALVE (L H ) SYSTEM” IS DISPLAYED 1040
AS-20 FAILURE CODE 8 5 “FAILURE IN PRESSURE CONTROL VALVE (R H ) SYSTEM:PRESSURE CONTROL VALVE (R H ) DOES NOT CLOSE” IS DISPLAYED 1041
AS-21 FAILURE CODE 8 6 “FAILURE IN PRESSURE CONTROL VALVE (L H ) SYSTEM:PRESSURE CONTROL VALVE (L H ) DOES NOT CLOSE” IS DISPLAYED 1042
AS-22 FAILURE CODE 8 7 “FAILURE IN PRESSURE CONTROL VALVE (R H ) SYSTEM:PRESSURE CONTROL VALVE (R H ) DOES NOT OPEN” IS DISPLAYED 1043
AS-23 FAILURE CODE 8 9 “SHORT CIRCUIT WITH CHASSIS GROUND IN PRESSURE SWITCH VALVE SYSTEM” IS DISPLAYED 1044
AS-24 FAILURE CODE 9 0 “DISCONNECTION IN PRESSURE SWITCH VALVE SYSTEM” IS DISPLAYED 1045
AS-25 FAILURE CODE 9 1 “FAILURE IN PRESSURE SWITCH VALVE SYSTEM:VALVE DOES NOT CLOSE” IS DISPLAYED 1046
AS-26 FAILURE CODE 9 2 “FAILURE IN PRESSURE SWITCH VALVE SYSTEM:VALVE DOES NOT OPEN” IS DISPLAYED 1047
AS-101 NOTHING IS DISPLAYED ON DISPLAY WINDOW OF CONTROLLER 1048
AS-102 FAILURE CODE IS KEPT CLEARED (“–” IS ALWAYS DISPLAYED IN DISPLAY WINDOW OF CONTROLLER) OR CANNOT BE CLEARED 1049
AS-103 ANOTHER CONTROLLER HAS A FAILURE 1050
AS-104 MONITOR LAMP (BUZZER) STAYS ON (OR OFF) 1051
AS-105 DISCONNECTION IN SWITCH SYSTEM OF ASR SYSTEM 1052
AS-106 SHORT CIRCUIT WITH CHASSIS GROUND IN SWITCH SYSTEM OF ASR SYSTEM 1053
AS-107 ASR WORKING LAMP DOES NOT LIGHT UP 1054
AS-108 ASR WORKING LAMP REMAINS LIT 1056
VHMS MACHINE HEALTH DIAGNOSIS SYSTEM (OP) 1059
1 BSAIC PRECAUTIONS 1060
1-1 OPERAION, SAFETY, INSPECITON AND MAINTENANCE OF MACHINE 1060
1-2 OPERATION OF MONITORING SYSTEM 1060
1-3 CONSTANT POWER SUPPLY (BATERY DIRECT POWER SUPPLY) 1060
1-4 PRECAUTIONS AT THE TIME OF TURNING ON THE POWER FOR VHMS 1061
1-5 PRECAUTIONS AT THE TIME OF REPLACING VHMS AND TRANSMISSION CONTROLLER 1061
1-6 OPERATION OF COMMUNICATION (ORB ORB COMMUNICATION) CONTROLLER 1062
2 OVERVIEW 1063
2-1 APPLICABLE MODEL 1063
2-2 BASIC CONFIGURATION (1) AND (2) 1063
2-3 INSTALLATION DRAWING 1066
3 STRUCTURE AND FUNCTION 1068
3-1 VHMS CONTROLLER 1068
3-2 BLOW-BY GAS SENSOR 1068
3-3 ENGINE OIL TEMPERAUTRE SENSOR 1069
3-4 AMPLIFIER FOR EXHAUST GAS TEMPERATURE SENSOR 1070
3-5 COMMUNICATION (ORB ORB COMMUNICATION) CONTROLLER/ANTENNA 1070
4 TROUBLESHOOTING 1072
4-1 TROUBLESHOOTING EQUIPMENT LIST 1072
4-2 CONNECTOR TYPE AND MOUNTING LOCATIONS 1073
4-3 CONNECTOR ARRANGEMENT DIAGRAM 1074
4-4 ELECTRICAL CIRCUIT DIAGRAM 1079
4-5 ERROR CODE LIST 1081
4-6 STANDARD VALUE TABLE FOR ELECTRICAL PARTS 1082
4-7 TROUBLE PHENOMENA LIST 1084
5 DISASSEMBLY AND ASSEMBLY 1096
5-1 REMOVAL AND INTRALLATION OF VHMS CONTROLLER 1096
5-2 REMOVAL AND INSTALLATION OF BLOW-BY GAS SENSOR 1097
5-3 REMOVAL AND INSTALLATION OF BREATHER 1097
5-4 REMOVAL AND INSTALLATION OF ENGINE OIL TEMPERATURE SENSOR 1098
5-5 REMOVAL AND INSTALLATION OF EXHAUST GAS TEMPERATURE SENSOR 1098
5-6 REMOVAL AND INSTALLATION OF EXHAUST GAS TEMPERATURE AMPLIFIER 1099
5-7 REMOVAL AND INSTALLATION OF SNAPSHOT SWITCH 1099
5-8 REMOVAL AND INSTALLATION OF COMMUNICATION (ORB ORG COMMUNICATION) CONTROLER AND ANTENNA 1100
6 SETTING OF VHMS CONTROLLER 1101
6-1 SETTING OF CHMS CONTROLLER 1101
6-2 SETTING ITEM 1101
6-3 SRTTING FLOW (OUTLINE) 1101
6-4 CHECK OF OPERATION AND PERFORMANCE 1102
6-5 DATA COLLECTION 1102
7 DATA RECOVERY AND TRANSMISSION 1103
7-1 DATA RECOVERY 1103
8 INSPECTION AND MAINTEANCE 1108
8-1 INSPECTION TIMING: INSPECTION AND MAINTENANCE TIMING OF MACHINE 1108
8-2 INSPECTION ITEM 1108
9 REPLACEMENT OF PARTS 1109
9-1 WHEN THE CHMS CONTROLLER IS REPLACED 1109
9-2 WHEN COMMUNICATION CONTROLLER IS REPLACED 1109
PROCEDURE Ⅰ FOR INITIAL SETUP OF VHMS 1110
PROCEDURE Ⅱ FOR OPENING ORBCOMM SERVICE 1112
30 DISASSEMBLY AND ASSEMBLY 1117
METHOD OF USING MANUAL 1119
PRECAUTIONS WHEN CARRYING OUT OPERATION 1120
SPECIAL TOOL LIST 1122
STARING MOTOR 1125
REMOVAL AND INSTALLATION 1125
ALTERNATOR 1126
REMOVAL AND INSTALLATION 1126
ENGINE OIL COOLER 1127
REMOVAL AND INSTALLATION 1127
LEFT BANK FUEL INJECTION PUMP 1128
REMOVAL AND INSTALLATION 1128
RIGHT BANK FUEL INJECTION PUMP ASSEMBKY (WITHOUT GOVERNOR) 1129
REMOVAL AND INSTALLATION 1129
AIR COMPRESSOR 1130
REMOVAL AND INSTALLATION 1130
WATER PUMP 1131
REMOVAL AND INSTALLATION 1131
AFTERCOOLER CORE 1132
REMOVAL 1132
INSTALLATION 1133
TURBOCHARGER 1134
REMOVAL AND INSTALLATION 1134
NOZZLE HOLDER 1135
REMOVAL AND INSTALLATION 1135
CYLINDER HEAD 1136
REMOVAL 1136
INSTALLATION 1137
EXHAUST BRAKE 1139
REMOVAL AND INSTALLATION 1139
ENGINE 1140
REMOVAL 1140
INATALLATION 1144
ENGINE FRONT SEAL 1145
REMOVAL AND INSTALLATION 1145
ENGINE REAR SEAL 1148
REMOVAL AND INSTALLATION 1148
RADIATOR TORQUE CONVERTER COOLER 1152
REMOVAL 1152
INSTALLATION 1153
BRAKE COOLER 1154
REMOVAL AND INSTALLATION 1154
OUTPUT SHAFT 1155
REMOVAL AND INSTALLATION 1155
DISASSEMBLY 1157
ASSEMBLY 1158
TORQUE CONVERTER, TRANSMISSION 1160
REMOVAL 1160
INSTALLATION 1162
PROCEDURE FOR CENTERING THE ENGINE ASSEMBLY AND TROQUE CONVERTER, TRANSMISSION ASSEMBLY 1163
TORQUE CONVERTER, CONTROL VALVE 1164
REMOVAL AND INSTALLATION 1164
DISASSEMBLY AND ASSEMBLY 1165
TORQUE CONVERTER AND TRANSMISSION 1166
DISCONNECTION 1166
CONNECTION 1167
TORQUE CONVERTER, PTO 1168
DISASSEMBLY 1168
ASSEMBLY 1174
TRANSMISSION 1180
DISASSEMBLY 1180
ASSEMBLY 1194
ECMV 1211
DISASSEMBLY AND ASSEMBLY 1211
DIFFERENTIAL (FOR STANFARD DIFFERENTIAL) 1213
REMOVAL 1213
INSTALLATION 1214
DISASSEMBLY 1215
ASSEMBLY 1219
DIFFERENTIAL (WITH DIFFERENTIAL LOCK) 1228
REMOVAL 1228
INSTALLATION 1229
DISASSEMBLY 1230
ASSEMBLY 1235
FRONT WHEEL 1245
REMOVAL AND INSTALLATION 1245
REAR WHEEL 1246
REMOVAL 1246
INSTALLATION 1247
FRONT BRAKE CALIPER 1248
REMOVAL AND INSTALLATION 1248
DISASSEMBLY 1249
ASSEMBLY 1250
FRONT BRAKE CALIPER PAD 1252
REMOVAL AND INSTALLATION 1252
FRONT WHEEL HUB 1253
DISASSEMBLY 1253
ASSEMBLY 1255
FINAL DRIVE CARRIER 1258
REMOVAL AND INSTALLATION 1258
DISASSEMBLY AND ASSEMBLY 1259
FINAL DRIVE 1260
DISASSEMBLY 1260
ASSEMBLY 1262
REAR BRAKE 1264
REMOVAL AND INSTALLATION 1264
REAR WHEEL BRAKE 1265
DISASSEMBLY 1265
ASSEMBLY 1266
PARKING BRAKE PAD 1268
REMOVAL 1268
INSTALLATION 1269
PARKING BRAKE CALIPER 1270
REMOVAL AND INSTALLATION 1270
DISASSEMBLY AND ASSEMBLY 1272
FRONT SUSPENDION CYLINDER 1273
REMOVAL AND ISNTALLATION 1273
DISASSEMBLY (STANDARD CYLINDER) 1274
ASSEMBLY (STANDARD CYLINDER) 1275
DISSASSEMBLY (CYLINDER WITH BUFFER RING) 1276
ASSEMBLY (CYLINDER WITH BUFFER RING) 1277
KING PIN 1279
REMOVAL AND INSTALLATION 1279
VARIBLE DAMPING SELECTIOR VALVE 1280
DISASSEMBLY 1280
ASSEMBLY 1281
REAR SUSPENSION CYLINDER 1282
REMOVAL AND INSTALLATION 1282
DISASSEMBLY (STANDARD CYLINDER) 1283
ASSEMBLY (STANDARD CYLINDER) 1284
DISASSEMBLY (CYLINDER WITH BUFFER RING) 1285
ASSEMBLY (CYLINDERWITH BUFFER RING) 1286
AIR GOVERNOR 1287
REMOVAL AND INATALLATION 1287
DISASSEMBLY AND ASSEMBLY 1288
BRAKE VALVE 1289
REMOVAL AND INSTALLATION 1289
DISASSEMBLY 1290
ASSEMBLY 1292
PARKING VRAKE CHAMBER 1294
REMOVAL AND INSTALLATION 1294
DISASSEMBLY 1295
ASSEMBLY 1296
REAR BRAKE VHAMBER 1298
REMOVAL AND INSTALLATION 1298
DISASSEMBLY 1299
ASSEMBLY 1303
FRONT BRAKE CHAMBER 1306
DISASSEMBLY 1306
ASSEMBLY 1308
SLACK ADJUSTER 1310
REMOVAL AND INSTALLATION 1310
DISASSEMBLY AND ASSEMBLY 1311
AIR DRIER (DESICCANT TYPE) 1312
REMOVAL AND INSTALLATION 1312
DISASSEMBLY AND ASSEMBLY 1313
BRAKE COLLING PUMP 1330
REMOVAL AND INSTALLATION 1330
STEERING, HOIST PUMP 1331
REMOVAL AND INSTALLATION 1331
TORQUE CONVERTER, TRANSMISSION PUMP 1332
REMOVAL AND INSTALLATION 1332
EMERGENCY STEERING MOTOR PUMP 1333
REMOVAL AND INSTALLATION 1333
STEERING VALVE 1334
REMOVAL AND INSTALLATION 1334
DISASSEMBLY 1335
ASSEMBLY 1339
BRAKE CONTROL VALVE (BCV) 1346
REMOVAL AND INSTALLATION 1346
DEMAND VALVE 1347
REMOVAL AND INSTALLATION 1347
DISASSEMBLY AND ASSEMBLY 1348
RELIEF VALVE 1349
DISASSEMBLY AND ASSEMBLY 1349
HOIST VALVE 1350
REMOVAL AND INSTALLATION 1350
DISASSEMBLY AND ASSEMBLY 1352
STEERING CYLINDER 1354
REMOVAL AND INSTALATION 1354
DISASSEMBLY 1355
ASSEMBLY 1357
HOIST CYLINDER 1360
REMOVAL AND INSTALLATION 1360
DISASSEMBLY 1361
ASSEMBLY 1362
BODY 1363
REMOVAL 1363
INSTALLATION 1364
CONTROLLER 1365
REMOVAL AND INSTALLATION 1365
AIR CONITIONER COMPRESSOR 1366
REMOVAL AND INSTALLATION 1366
RECEIVER TAKE 1367
REMOVAL AND INSTALLATION 1367
AIR CONDITIONER CONDENSER 1368
REMOVAL AND INSTALLATION 1368
40 MAINTENANCE STANDARD 1369
OUTPUT SHAFT 1370
TURQUE CONVERTER VALVE 1371
TORQUE CONVERTER 1372
TRANSMISSION 1374
ECMV (ELECTRONIC CONTROL MODULATION VALVE) 1379
FRONT AXLE 1380
FRONT AXLE (WITH ABS/ASR) (IF EQUIPPED) 1382
REAR AXLE SUPPORT (HD785-5) 1384
REAR AXLE SUPPORT (HD985-5) 1385
DIFFERENTIAL 1387
FINAL DRIVE (HD785-5) 1389
FINAL DRIVE (HD985-5) 1392
FRONT BRAKE 1394
REAR BRAKE 1395
REAR BRAKE (WITH ABS/ASR) (IF EQUIPPED) 1397
PARKING BRAKE 1399
STEERING LINKAGE 1400
FRONT SUSPENSION CYLINDER 1402
REAR SUSPENSION CYLINDER 1403
PARKING BRAKE CHAMBER 1404
SLACK ADJUSTER 1405
HYDRAULIC PUMP (SAR-160) (FOR TORQUE CONVERTER AND TRANSMISSION) 1406
HYDRAULIC PUMP (SAR4-180+180:FOR STEERING,WORK EQUIPMENT) (SAR4-285+285:FOR BRAKE COOLING) 1407
DEMAND VALVE 1408
CROSS-OVER RELIEF VALVE 1408
HOIST VALVE 1409
STEERING CYLINDER 1410
HOIST CYLINDER 1411
90 OTHERS 1413
ELECTRICAL CIRCUIT DIAGRAM 1415
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH MECHANICAL GOVERNOR) (1/3) 1415
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH MECHANICAL GOVERNOR) (2/3) 1417
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH MECHANICAL GOVERNOR) (3/3) 1419
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH ELECTRONIC GOVERNOR) (1/5) 1421
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH ELECTRONIC GOVERNOR) (2/5) 1423
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH ELECTRONIC GOVERNOR) (3/5) 1425
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH ELECTRONIC GOVERNOR) (4/5) 1427
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH ELECTRONIC GOVERNOR) (5/5) 1429
ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (1/2) 1431
ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (2/2) 1433
ELECTRICAL CONTROL SYSTEM 1435
ELECTRICAL CIRCUIT DIAGRAM 1435
AUTOMATIC SHIFT CONTROL SYSTEM 1437
ELECTRICAL CIRCUIT DIAGRAM (1/2) 1437
ELECTRICAL CIRCUIT DIAGRAM (2/2) 1439
AUTOMATIC SUSPENSION SYSTEM 1441
SYSTEM CIRCUIT DIAGRAM (1/2) 1441
SYSTEM CIRCUIT DIAGRAM (2/2) 1443
PAYLOAD METER (PRINTER TYPE) (OP) 1445
ELECTRICAL CIRCUIT DIAGRAM 1445
PAYLOAD METER Ⅱ(CARD TYPE) (OP) 1447
ELECTRICAL CIRCUIT DIAGRAM 1447
PMC SYSTEM (OP) 1449
ELECTRICAL CIRCUIT DIAGRAM (1/2) 1449
ELECTRICAL CIRCUIT DIAGRAM (2/2) 1453
ASR-Ⅱ SYSTEM (OP) 1453
ELECTRIAL CIRCUIT DIAGRAM 1453
AIR CIRCUIT DIAGRAM 1455
ELECTRICAL CIRCUIT DIAGRAM 1457
ENGINE CONTROL SYSTEM 1457
TRANSMISSION CONTROL SYSTEM 1459
1 ELECTRIC GOVENOR SPECIFICATION 1459
2 MECHANICAL GOVENOR SPECIFICATION 1461
4-4 ELECTRICAL CIRCUIT DIAGRAM 1463

DESCRIPTION:

Komatsu HD785-5 HD985-5 Dump Truck Shop Manual SEBM013918 – 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:

PRECAUTIONS DURING WORK :

S.V 26/12/24