Komatsu HD465-5 HD605-5 Dump Truck Shop Manual SEBM015209 PDF

Description

Komatsu HD465-5 HD605-5 Dump Truck Shop Manual SEBM015209 – PDF DOWNLOAD

FILE DETAILS:

Komatsu HD465-5 HD605-5 Dump Truck Shop Manual SEBM015209 – PDF DOWNLOAD 

Language : English
Pages : 1206
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu HD465-5 HD605-5 Dump Truck Shop Manual SEBM015209 – PDF DOWNLOAD 

MACHINE MODEL   SERIAL NUMBER
HD465-5                    4626 and up
HD605-5                    1013 and up

COVER 1
CONTENTS 2
01 GENERAL 28
GENERAL ASSEMBLY DRAWING 29
SPECIFICATIONS 30
WEIGHT TABLE 36
LIST OF LUBRICANT AND WATER 37
10 STRUCTURE AND FUNCTION 38
RADIATOR, TORQUE CONVERTER, OIL COOLER, AFTER COOLER, WORK EQUIPMENT OIL COOLER 40
BRAKE OIL COOLER 41
POWER TRAIN SKELETON 42
OUTPUT SHFT 43
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING 44
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM 45
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT SCHEMATICS 46
TORQUE CONVERTER 47
LOCKUP SOLENOID VALVE 52
TRANSMISSION 53
TRANSMISSION VALVE 57
ECMV(ELECTRONIC CONTROL MODULATION VALVE 58
LUBRICATION RELIEF VALVE 63
FRONT AXLE 64
REAR AXLE 65
DIFFERENTIAL 66
FINAL DRIVE 67
FRONT BRAKE 68
REAR BRAKE 69
PARKING BRAKE 70
WHEELS 71
AXLE SUPPORT 72
STEERING SYSTEM 73
STEERING WHEEL 74
STEERING LINKAGE 75
SUSPENSION SYSTEM 77
SUSPENSION CYLINDER 79
AIR PIPING 84
AIR CIRCUIT DIAGRAM 86
DESICCANT TYPE AIR DRIER 88
AIR GOVERNOR 89
SAFETY VALVE 89
CHECK VALVE 90
DOUBLE CHECK VALVE 90
AUTO DRAIN VALVE 91
HAND BRAKE VALVE 92
BRAKE VALVE 93
REDUCING VALVE 94
EMERGENCY BRAKE CONTROL VALVE 96
PARKING BRAKE CONTROL VALVE 99
RELAY VALVE 100
PARKING BRAKE RELAY VALVE 103
QUICK-RELEASE VALVE 105
PARKING BRAKE CHAMBER 105
FRONT BRAKE CHAMBER 106
REAR BRAKE CHAMBER 107
SLACK ADJUSTER 110
AIR DRIER (DESICCANT TYPE) 111
HYDRAULIIC PIPING 113
HYDRAULIC CIRCUIT DIAGRAM 115
DUMP BODY CONTROL 116
HYDRAULIC TANK AND BRAKE COOLING OIL TANK 117
BRAKE COOLING OIL CONTROL VALVE(BCV) 118
STEERING CONTROL VALVE 119
DEMAND VALVE 123
CROSS-OVER RELIEF VALVE 127
HOIST VALVE 128
STEERING CYLINDER 130
HOIST CYLINDER 130
ELECTRICAL CIRCUIT DIAGAM 131
STOP LAMP SWITCH 136
EXHAUST BRAKE SWITCH 136
FRONT BRAKE CUT-OFF VALVE 137
OVERRUN PREVENTION VALVE 138
EXHAUST BRAKE VALVE 138
HORN VALVE 139
PARKING BRAKE SWITCH 139
AIR CONDIYIONER 140
PIPING DIAGRAM 140
ELECTRICAL CIRCUIT DIAGRAM 141
REFRIGERANT CIRCUIT DIAGRAM 143
UNIT 144
RECEIVER DRYER 145
CONDENSER 145
COMPRESSOR 146
ENGINE CONTROL SYSTEM 147
SYSTEM DRAWING 147
AISS 148
FUEL INJECTION PUMP ELECTRONIC GOVERNOR 149
HYDRAULIC CIRCUIT DIAGRAM 150
ENGINE CONTROLLER 151
SENSORS, SWITCHES 151
ELECTRICAL CIRCUIT DIAGRAM 152
APS 153
EXHAUST BRAKE 155
SYSTEM DIAGRAM 155
SYSTEM CIRCUIT DIAGRAM 156
AUTOMATIC RETARD SPEED CONTROL SYSTEM 158
SYSTEM DRAWING 158
STRUCTURE OF SYSTEM 159
ELECTRICAL CIRCUIT DIAGRAM 160
AIR CIRCUIT DIAGRAM 161
AUTOMATIC RETARD SPEED CONTROL 162
AUTOMATIC RETARD SPEED CONTROLLER 163
AUTOMATIC SHIFT CONTROL SYSYTEM 164
SYSTEM DIAGRAM 164
ELECTRICAL CIRCUIT DIAGRAM 166
TRANSMIAAION CONTROLLER 167
CONNECTOR SIGNALS 168
SELF-DIAGNOSTIC FUNCTION 168
SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFTING RANGES 169
AUTOMATIC GEAR SHIFTING LINE GRAPH 170
SHIFT LEVER SWITCH 173
SENSORS, SWITCHES 174
ENGINE SPEED SENSOR 174
TRANSMISSION SPEED SENSOR 174
TRANSMISSION OIL TEMPERATURE SENSOR 174
FILL SWITCH 175
ACCELERATOR SENSOR 176
SHIFT LIMIT SWITCH 177
MODE SELECTOR SWITCH 177
AUTOMATIC EMERGENCY STEERING SYSTEM 178
SYSTEM DIAGRAM 178
ELECTRICAL CIRCUIT DIAGRAM 179
FLOW SWITCH 180
RELAY TIMER 182
AUTOMATIC SUSPENSION SYSTEM 183
STRUCTURE OF SYSTEM 184
SYSTEM CIRCUIT DIAGRAM 185
AUTOMATIC SUSPENSION MODE SELECTION CONTROL 186
SUSPENSION CONTROLLER 187
SENSORS, SWITCHES 188
STEERING ANGLE SENSOR 188
PRESSURE SENSOR 188
SELF-DIAGNOSTIC FUNCTION 189
PAYLOAD METER (PRINTER TYPE) 190
STRUCTURE OF SYSTEM 190
ELECTRICAL CIRCUIT DIAGRAM 191
PRINCIPLE OF CALCULATION 192
FEATURES OF EQUIPMENT 194
1 PAYLOAD METER 194
2 PRESSURE SENSOR 197
3 CLINOMETER 198
4 LAMP DRIVE RELAY 198
SELF-DIAGNOSTIC FUNCTION 199
PAYLOAD METER Ⅱ (CARD TYPE) 200
STRUCTURE OF SYSTEM 200
ELECTRICAL CIRCUIT DIAGRAM 201
PRINCIPLE OF MEASUREMNT 202
FEATURES OF EACH DEVICE 203
1 PAYLOAD METER Ⅱ 203
LEFT FACE 204
2 PRESSURE SENSOR 231
3 CLINOMETER 232
4 LAMP DRIVE RELAY 232
5 SELF-DIAGNOSTIC FUNCTION 233
MACHINE MONITOR SYSTEM 239
SYSTEM DRAWING 239
MONITOR PANEL DIAGRAM 241
MACHINE MONITOR NORMAL DISPLAY FUNCTIONS 242
SELF-DIAGNOSTIC FUNCTION WHEN STARTING SWITCH IS OPERATED 249
TRAVEL SPEED COMPENSATION ROTARY SWITCH 249
SENSORS,SWITCHES 250
ENGINE OIL PRESSURE 250
FUEL LEVEL SENSOR 251
ENGINE WATER TEMPERATURE SENSOR 252
RETARDER OIL TEMOERATURE SENSOR 252
TORQUE CONVERTER OIL TEMPERATURE SENSOR 252
AIR PRESSURE SENSOR 252
RADIATOR WATER LEVEL SENSOR 253
TRANSMISSION OIL FILTER SENSOR 253
STEERING OIL TEMPERATURE SENSOR 254
BRAKE STROKE SENSOR 254
BODY SEATED SWITCH 255
TILT SWITCH 256
20 TESTING AND ADJUSTING 257
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS 258
STANDARD VALUE TABLE FOR CHASSIS 259
STANDARD VALUE TABLE FOR ELECTRICAL PARTS 264
TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 275
ADJUSTING VALVE CLEARANCE 277
MEASURING COMPRESSION PRESSURE 278
MEASURING BLOW-BY 279
ADJUSTING FUEL INJECTION TIMING 280
BLEEDING AIR FROM FUEL-INJECTION PUMP 282
ADJUSTING ENGINE STOP MOTOR CABLE 283
ADJUSTING ACCELERATOR PEDAL 284
ADJUSTING ENGINE,TRANSIMSSION SPEED SENSORS 285
TESTING HYDRAULIC PRESSURE OF TORQUE CONVERTER VALVE 286
TESTING ECMV HYDRAULIC PRESSURE 287
TESTING TORQUE CONVERTER STALL SPEED 290
TESTING BRAKE PRESSURE 292
BLEEDING AIR FROM BRAKE CIRCUIT 293
TESTING AND ADJUSTING PARKING BRAKE PERFORMANCE 294
TESTING WEAR OF FRONT BRAKE PAD 295
TESTING WEAR OF REAR BRAKE DISC 296
TESTING AND ADJUSTING SUSPENSION CYLINDER 297
TESTING AND ADJUSTING AIR PRESSURE IN AIR CIRCUIT 303
INSPECTION OF AIR DRIER (DESICCANT TYPE) 304
ADJUSTING HOIST LEVER LINKAGE 306
ADJUSTING BODY POSITIONER 307
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING, HOIST CIRCUIT 308
AIR BLEEDING FROM STEERING CYLINDER 310
ADJUSTING ELECTRONIC MONITOR 311
ADUSTING Q [FUEL INJECTION AMOUNT] WHEN REPLACING ENGINE CONTROLLER 312
SETTING ROTARY SWITCH WHEN REPLACING TRANSMISSION CONTROLLER 313
METHOD OF DELETING DATA FROM ENGINE CONTROLLER, TRANSMISSION CONTROLLER MEMORY(CONTROL FROM MONITOR PANEL) 314
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM 317
PROCEDURE FOR OPERATING MODULATION CHECKER 323
PERFORMONG PM CLINIC USING MANUAL SNAPSHOT(=QUICK PM) 328
PM-CLINIC SERVICE 332
TROUBLESHOOTING 334
POINTS TO REMEMBER WHEN TROUBLESHOOTNG 335
SEQUENCE OF EVENTS IN TROUBLESHOOTING 336
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 337
CHECKS BEFORE TROUBLESHOOTING 345
TYPE OF CONNECTOR AND POSITION OF INSTALLATION 347
CONNECTOR PIN ALLOCATION CHART 352
CONNECTION TABLE FOR CONNECTOR PIN NUKBERS 357
EXPLANATIONS OF FUNCTIONS (CONTROL MECHANISM) OF ELECTRICAL SYSTEM 384
MONITOR PANEL USER COSDES AND SERVICE MODE FUNCTION 389
SELF-DIAGNOSTIC DISPLAY METHOD FOR MONITOR PANEL AND CONTROLLERS 405
TABLE OF SERVICE CODES AND USER CODES 412
METHOD OF USING JUDGMENT TABLE 422
METHOD OF USING TROUBLESHOOTING CHARTS 423
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (ELECTRONIC GOVERNOR SPECIFICATION G MODE) 425
ACTION TAKEN BY SELF-DIAGNOSTIC AND PROB-LEMS ON MACHINE 426
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER, TRANSMISSION RELATED PARTS 434
G-1 [0 0] (OFF) OR C010 [E <–>1 0] ABNORMALITY IN POWER SOURCE 438
G-2 C011 [E <–>1 1] ABNORMALITY IN CONTROLLER 438
G-3 C012 [E <–>1 2] ABNORMALITY IN RACK SENSOR SYSTEM 439
G-4 C014 [E <–>1 4] ABNORMALITY IN GOVERNOR SOLENOID SYSTEM 440
G-5 C016 [E <–>1 6] ABNORMALITY IN GOVERNOR CUT RELAY SYSTEM 441
G-6 C018 [E <–>1 8] ABNORMALITY IN RACK SENSOR POWER SOURCE SYSTEM 442
G-7 C019 [E <–>1 9] ABNORMALITY IN GOVERNOR SERVO SYSTEM BANK 443
G-8 C01b [E <–>1 6] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM A 444
G-9 C01c [E <–>1 C] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM B 445
G-10 C01d [E <–>1 d] ABNORMALITY IN PRE-STROKE SOLENOID SYSTEM 446
G-11 C021 [E <–>2 1] MISTAKEN CONNECTION OF CONNECTOR 447
G-12 C022 [E <–>2 2] ENGINE OVERRUN 448
G-13 C023 [E <–>2 3] ENGINE OVERHEATING 448
G-14 C024 [E <–>2 4] DROP IN ENGINE OIL PRESSURE 448
G-15 C031 [E <–>3 1] ABNORMALITY IN ACCELERATON SENSOR SYSTEM 449
G-16 C034 [E <–>3 4] ABNORMALITY IN ENGINE WATER TEMPERATURE SYETEM 452
G-17 C036 [E <–>3 6] ABNORMALITY IN ENGINE OIL PRESSURE SENSOR 453
G-18 C055 [E <–>5 5] ABNORMALITY IN NETWORK 454
G-19 C056 [E <–>5 6] ABNORMALITY IN SOLENOID POWER SOURCE SYSTEM RIGHT 455
G-20 C058 [E <–>5 8] ABNORMALITY IN BACKUP POWER SOURCE SYSTEM 456
G-21 C059 [E <–>5 9] ABNORMALITY IN BACKUP SOURCE SYSTEM 457
G-22 C0C2 [E <–>C 2] DEFECTIVE MODEL SELECTION DATA 458
G-23 C0C4 [E <–>C 4] ABNORAMLITY IN ACCELERATION SENSOR SYSTEM 459
G-24 C0C5 [E <–>C 5] ABNORAMLITY IN IDLING VALIDATION 462
G-25 ENGINE DOES NOT START 464
G-26 DEFECTIVE ACTUATION OF APS 467
TROUBLESHOOTING OF ENGINE SYSTEM (S MODDE) 475
METHOD OF USING TROUBLESHOOTING CHART 476
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 480
S-2 ENGINE DOES NOT START 482
a) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT(FUEL IS NOT BEING INJECTED) 482
b) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START(FUEL IS BEING INJECTED) 483
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 484
S-4 ENGINE STOPS DURING OPERATIONS 485
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 487
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER) 488
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTON) 489
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE 490
S-9 OIL BECOMES CONTAMINATED QUICKLY 491
S-10 FUEL CONSUMPTION IS EXCESSIVE 492
S-11 OIL IS COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN 493
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) 494
S-13 OIL LEVEL RISES 495
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 496
S-15 ABNORMAL NOISE IS MADE 497
S-16 VIBRATION IS EXCESSIVE 499
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A MODE) 500
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM 503
ACTION TAKEN BY SELF-DIAGNOSTIC AND PROBLEMS ON MACHINE 505
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER, TRANSMISSION RELATED PARTS 525
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM 527
A-1 ABNORMALITY IN POWER SOURCE SYSTEM 528
a) [u u] [OFF] CONTROLLER SELF-DIAGNOSTIC DISPLAY LED DOES NOT LIGHT UP 528
b) bOO1 [E <–>0 1, E C<–>0 1] DROP IN VOLTAGE OF CONTROLLER POWER SOURCE IS DISPLAYED 529
c) bOdA [E <–>d A, E C<–>d A] DROP IN VOLTAGE OF BATTERY DIRECT POWER SOURCE IS DISPLAYED 530
d) bOdb [E <–>d b, E C<–>d b] DROP IN VOLTAGE OF MAIL POWER SOURCE IS DISPLAYED 531
e) bOO2 [E <–>0 2, E C<–>0 2] ABNORMALITAY IN TRANSMISSION CUT RELAY POWER SOURCE IS DISPLAYED 532
A-2 bOO3 [E <–>0 3, E C<–>0 3] ABNORMALITY IN NEUTRAL SAFETY SYSTEM IS DISPLAYED 533
A-3 bOO5 [E <–>0 5, E C<–>0 5] DOUBLE ENGAGEMENT FOR CLUTCH IS DISPLAYED 534
A-4 bOO6 [E <–>0 6, E C<–>0 6] ABNORMALITY IN TRANSMISSION [CUT RELAY] SYSTEM DISPLAYED 535
A-5 bOO8 [E <–>0 8, E C<–>0 8] ABNORMALITY IN REAR BRAKE SOLENOID SYSTEM IS DISPLAYED 536
A-6 bOO9 [E <–>0 9,E C<–>0 9] ABNORMALITY IN EXHAUST BRAKE SOLENOID SYSTEM IS DISPLAYED 537
A-7 538
a) bOC4 [E <–>C 4, E C<–>C 4] SHORT CIRCUIT WITH GROUND IN BCV REAR SOLENOID IS DISPLAYED 538
b) bOC6 [E <–>C 6, E C<–>C 6] SHORT CIRCUIT IN BCV REAR SOLENOID IS DISPLAYED 539
c) bOC8 [E <–>C 8, E C<–>C 8] DISCONNECTION IN BCV REAR SOLENOID IS DISPLAYED 540
A-8 ABNORMALITY IN SPEED SENSOR SYSTEM 541
a) b010 [E <–>1 0, E C<–>1 0] OR b060 [E <–>6 0, E C<–>6 0] DISCONNECTION IN ENGINE SPEED SENSOR [B] SYSTEM IS DISPLAYED (ELECTRONIC GOVERNOR SPECIFICATION MACHINE) OR FAILURE OF ENGINE SPEED IS DISPLAYED (ELECTRONIC GOVERNOR SPECIFICATION MACHINE) 541
b) b011 [E <–>1 1, E C<–>1 1] OR b061 [E <–>6 1, E C<–>6 1] DISCONNECTION IN INPUT SHAFT SPEED SENSOR SYSTEM IS DISPLAYED OR FAILURE OF INPUT SHAFT SPEED SENSOR IS DISPLAYED 542
c) b012 [E <–>1 2, E C<–>1 2] OR b062 [E <–>6 2, E C<–>6 2] DISCONNECTION IN INTERMEDIATE SHAFT SPEED SENSOR SYSTEM IS DISPLAYED OR FAILURE OF INTERMEDIATE SHAFT SPEED SENSOR IS DISPLAYED 543
d) b013 [E <–>1 3, E C<–>1 3] OR b063 [E <–>6 3, E C<–>6 3] DISCONNECTION IN TRAVEL SPEED SENSOR(TRANSMISSION OUTPUT SHAFT SPEED SENSOR)SYSTEM IS DISPLAYED OR FAILURE OF OUTPUT SHAFT SPEED SENSOR IS DISPLAYED 544
A-9 SPEED SENSOR SYSTEM, CLUTCH SLIPPING 545
a) b022 [E <–>2 2, E C<–>2 2] OR b023 [E <–>2 3, E C<–>2 3] INPUT SHAFT SPEED SENSOR OR H,L CLUTCH SYSTEM IS DISPLAYED 545
b) b024 [E <–>2 4, E C<–>2 4] – b028 [E <–>2 8, E C<–>2 8] TRAVEL SPEED SENSOR SYSTEM OR SPEED CLUTCH(1, 2, 3, 4, R)SYSTEM IS DISPLAYED 546
A-10 ABNORMALITY IN MODEL SELECTION (WIRING HARNESS) IS DISPLAYED 547
a) b014 [E <–>1 4, E C<–>1 4] ABNORMALITY IN MODEL SELECTION(WIRING HARNESS)IS DISPLAYED 547
b) b0A1 [E <–>A 1, E C<–>A 1] ABNORMALITY IN MODEL SELECTION(ROTARY SWITCH)IS DISPLAYED 548
A-11 ABNORMALITY IN SHIFT LEVER SYSTEM 549
a) b007 [E <–>0 7, E C<–>0 7] SHORT CIRCUIT IN SHIFT LEVER ASSEMBLY POWER SOURCE IS DISPLAYED 549
b) b015 [E <–>1 5, E C<–>1 5] SHIFT LEVER POSITION SIGNAL INPUT FOR 2 OR MORE SYSTEM IS DISPLAYED 550
c) b016 [E <–>1 6, E C<–>1 6] SHIFT LEVER POSITION SIGNAL IS NOT INPUT 552
A-12 b017 [E <–>1 7, E C<–>1 7] ABNORMALITY IN ACCELERATOR SIGNAL IS DISPLAYED 554
A-13 b019 [E <–>1 9, E C<–>1 9] ABNORMALITY IN TRANSMISSION OIL TRMPERATURE SENSOR IS DISPLAYED 555
A-14 ABNORMALITY IN PRESSURE CONTROL VALVE SYSTEM 556
a) b032 [E <–>3 2, E C<–>3 2] – b038 [E <–>3 8,E C<–>3 8] FILL SIGNAL(CLUTCH ON)IS DISPLAYED REGARDLESS OF COMMAND 556
b) b042 [E <–>4 2, E C<–>4 2] – b048 [E <–>4 8,E C<–>4 8] FILL SIGNAL IS NOT INPUT AND CLUTCH SLIPPING IS DISPLAYED 558
b-1) INSPECTING FILL SIGNAL SYSTEM 558
b-2) b042 [E <–>4 2, E C<–>4 2] ・ b043 [E <–>4 3,E C<–>4 3] INSPECTING TRANSMISSION INPUT SHAFT SPEED SIGNAL SYSTEM,H,L CLUTCH SYSTEM(CHECK CLUTCH SLIP) 559
b-3) b044 [E <–>4 4, E C<–>4 4] ・ b048 [E <–>4 8, E C<–>4 8] INSPECTING TRANSMISSION OUTPUT SHAFT SPEED SIGNAL SYSTEM,1-4,R CLUTCH SYSTEM(INSPECTING CLUTCH SLIP) 559
A-15 b052 [E <–>5 2, E C<–>5 2] – b058 [E <–>5 8, E C<–>5 8] WHEN FILL SIGNAL IS NOT INPUT(FLOW DETECTOR VALVE SYSTEM) 560
A-16 b071 [E <–>7 1, E C<–>7 1] – b078 [E <–>7 8, E C<–>7 8] SHORT CIRCUIT IN PRESSURE CONTROL VALVE SOLENOID SYSTEM IS DISPLAYED 561
A-16 b091 [E <–>9 1, E C<–>9 1] – b098 [E <–>9 8, E C<–>9 8] DISCONNECTION IN PRESSURE CONTROL VALVE SOLENOID SYSTEM IS DISPLAYED 561
A-17 ABNORMALITY IN SENSOR SYSTEM 563
a) b0A2 [E <–>A 2, E C<–>A 2] ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE SENSOR SYSTEM IS DISPLAYED 563
b) b0A3 [E <–>A 3, E C<–>A 3] ABNORMALITY IN FUEL LEVEL SENSOR SYSTEM IS DISPLAYED 564
c) b0b3 [E <–>b 3, E C<–>b 3] ABNORMALITY IN AIR PRESSURE SENSOR SYSTEM IS DISPLAYED 565
d) b0b4 [E <–>b 4, E C<–>b 4] ABNORMALITY IN RETARDER BRAKE OIL TEMPERATURE SENSOR IS DISPLAYED 566
A-18 WARNING DISPLAY 567
a) b0d1 [E <–>d 1, E C<–>d 1] TRANSMISSION FILTER CLOGGED WARNING IS DISPLAYED 567
b) b0d5 [E <–>d 5, E C<–>d 5] TILT WARNING IS DISPLAYED 568
c) b0d6 [E <–>d 6, E C<–>d 6] DROP IN RADIATOR WATER LEVEL WARNING IS DISPLAYED 569
d) b0d7 [E <–>d 7, E C<–>d 7] BATTERY CHARGE LEVEL WARNING IS DISPLAYED 570
e) b0E5 [E <–>E 5, E C<–>E 5] STEERING OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED 571
f) b0F6 [E <–>F 6, E C<–>F 6] REAR BRAKE OIL PRESSURE WARNING IS DISPLAYED 572
A-19 b0C1 [E <–>C 1, E C<–>C 1] ABNORMALITY IN CONNECTOR CONNECTION IS DISPLAYED 573
A-20 574
a) b0d2 [E <–>d 2, E C<–>d 2] TORQUE CONVERTER OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED 574
b) b0E9 [E <–>E 9, E C<–>E 9] AIR PRESSURE DROP WARNING IS DISPLAYED 574
c) b0F3 [E <–>F 3, E C<–>F 3] RETARDER BRAKE OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED 574
d) b0d8 [E <–>d 8, E C<–>d 8] ENGINE OVERRUN PREVENTION BRAKE ACTUATED (※1) OR ENGINT=E OVERRUN PREVENTION BRAKE ACTUATED 1 (※2) IS DISPLAYED 575
e) b0d9 [E <–>d 9, E C<–>d 9] ENGINE OVERSHOOT ACTUATED IS DISPLAYED 575
f) b0dF [E <–>d F, E C<–>d F] ENGINE OVERRUN PREVENTION ACTUATED 2 IS DISPLAYED 576
TEOUBLESHOOTING OF SUSPENSION CONTROLLER SYSTEM (SP MODE) 577
JUDGMENT TABLE FOR SUSPENSION CONTROLLER, SUSPENSION RELAED PARTS 578
ACTION TAKEN BYSELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE 580
ELECTRICAL CIRCUIT DIAGRAM OF SUSPENSION CONTROLLER SYSTEM 584
SP-1 d001 [ALL OFF or E <–>01] ABNORMALITY IN POWER SOURCE IS DISPLAYED 586
SP-2 d011 [E <–>11 IS DISPLAYED] ABNORMALITY IN PRESSURE SENSOR [RIGHT] SYSTEM IS DISPLAYED 587
SP-3 d012 [E <–>12 IS DISPLAYED] ABNORMALITY IN PRESSURE SENSOR [LEFT] SYSTEM IS DISPLAYED 588
SP-4 d015 [E <–>15 IS DISPLAYED] ABNORMALITY IN TRAVEL SPEED SENSOR SYSTEM IS DISPLAYED 589
SP-5 d016 [E <–>16 IS DISPLAYED] ABNORMALITY IN STEERING SENSOR SYSTEM IS DISPLAYED 590
SP-6 d0C2 [E <–>C2 IS DISPLAYED] DEFECTIVE MODEL SELECTION DATA IS DISPLAYED 591
SP-7 d021 [E <–>21 IS DISPLAYED] ABNORMALITY IN SOLENOID [1] SYSTEM IS DISPLAYED 592
SP-8 d022 [E <–>22 IS DISPLAYED] ABNORMALITY IN SOLENOID [2] SYSTEM IS DISPLAYED 593
SP-9 d023 [E <–>23 IS DISPLAYED] ABNORMALITY IN SOLENOID [3] SYSTEM IS DISPLAYED 594
SP-10 d0C1 [E <–>C1 IS DISPLAYED] DISCONNECTION IN NETWROK IS DISPLAYED 595
SP-11 d0C3 [E <–>C3 IS DISPLAYED] DEFECTIVE TRAVEL SPEED COMPENSATION DATA IS DISPLAYED 596
TROUBLESHOOTING OF PAYLOAD METER (PRINTER TYPE) SYSTEM (LP MODE) 597
SERVICE CODES AND SELF-DIAGNOSIS OF PAYLOAD METER (PRINTER TYPE) 598
ELECTRICAL CIRCUIT DIAGRAM FOR PAYLOAD METER (PRINTER TYPE) SYSTEM 599
LP-1 NO DISPLAY APPEARS WHEN STARTING SWITCH IS TURNED ON 601
LP-2 CALIBRATION DEMAND(CAL FLASHES) IS SHOWN CONTINUOUSLY AFTER STARTING SWITCH IS TUENED ON 602
LP-3 CALIBRATION CANNOT BE CARRIED OUT 603
LP-4 AFTER STARTING SWITCH IS TURNED ON, ALL EXTERNAL DISPLAY LAMPS DO NIOT LIGHT UP 606
LP-5 CONDITION DOES NOT EXIST FOR LAMPS TO LIGHT UP, BUT EXTERNAL DISPLAY LAMPS LIGHT UP 608
LP-6 LEVEL OF LIGHTING UP OF EXTERNAL DISPLAY LAMPS IS NOT CORRECT 609
LP-7 ABNORMALITY IN DISPLAY LOGIC 611
LP-8 E01-E04 IS DISPLAYED 616
LP-9 E11-E14 IS DISPLAYED 617
LP-10 E21-E28 IS DISPLAYED BY SENSOR CHECK 618
LP-11 E31 IS DISPLAYED 619
LP-12 E32 IS DISPLAYED 621
LP-13 E41 IS DISPLAYED 623
LP-14 E42 IS DISPLAYED 624
LP-15 PRINTER DOES NOT PRINT ANYTHING (BLANK PAPER COMES OUT) 625
LP-16 PRINTER PRINTS ONLY “NO DATA” 625
LP-17 PRINTER DOES NOT PRINT OUT WHEN PRT SWITCH IS PRESSED 625
LP-18 “PAPE”FLASHES 626
LP-19 TIME IS WRONG 626
LP-20 E33 IS DISPLAYED 626
TROUBLESHOOTING OF PAYLOAD METER Ⅱ (CARD TYPE)SYSTEM(LC NODE) 627
SERVICE CODES AND SELF-DIAGNOSIS OF PAYLOAD METER Ⅱ (CARD TYPE) 628
ELECTRICAL CIRCUIT DIAGRAM FOR PAYLOAD METER Ⅱ (CARD TYPE) SYSTEM 631
LC-1 NO DISPLAY APPEARS WHEN STARTING SWITCH IS TURNED ON 633
LC-2 AFTER STARTING SWITCH IS TURNED ON, ALL EXTERNAL DISPLAYED LAMPS DO NOT LIGHT UP 634
LC-3 CONDITION DOES NOT EXIST FOR LAMPS TO LIGHT UP, BUT EXTERNAL DISPLAY LAMPS LIGHT UP 635
LC-4 LEVEL OF LIGHTING UP OF EXTERNAL DISPLAY LAMPS IS NOT CORRECT 636
LC-5 CYCLE DATA IS NOT RECORDED, ON/OFF DATA IS NOT RECORDED:BATTERY CHARGE SIGNAL SYSTEM: ENGINE NOT STARTED IS DETECTED 638
LC-6 CALIBRATION CANNOT BE CARRIED OUT, TIME DISPLAY DOES NOT MATCH CONDITIONS: SHIFT LEVER N POSITION SIGNAL SYSTEM 639
LC-7 ABNORMALITY IN DISPLAY LOGIC 640
LC-8 B-FL REMAINS DISPLAYED AND DOES NOT CHANGE: BODY FLOAT RELAY SYSTEM: WHEN NOT DUMPING AND WHEN DUMP LEVER IS NOT AT FLOAT POSITION 642
LC-9 F-09 IS DISPLAYED: DROP IN VOLTAGE OF BACK-UP BATTERY BULIT INTO PAYLOAD METER 643
LC-10 FULL DISPLAY APPEARS 643
LC-11 F-20 IS DISPLAYED: SENSOR POWER SOURCE VOLTAGE SYSTEM 644
LC-12 F-21-F-24 IS DISPLAYED: DISCONNECTION, SHORT CIRCUIT WITH GROUND IN SUSPENSION PRESSURE SENSOR SYSTEM 645
LC-13 F-25-F-28 IS DISPLAYED: SHORT CIRCUIT IN SUSPENSION PRESSURE SENSOR SYSTEM POWER SOURCE 647
LC-14 F CAL IS DISPLAYED: CALIBRATION NOT CARRIED OUT, DAMAGED DATA INSIDE PAYLOAD METER 648
LC-15 F-41-F-45 IS DISPLAYED: SHORT CIRCUIT IN EXTERNAL DISPLAY LAMP SYSTEM POWER SOURCE 649
LC-16 L-BAD IS DISPLAYED : CYCLE DATA SAVED WHEN MACHINE WAS SWAYING 651
LC-18 F-31 IS DISPLAYED: DISCONNECTION, SHORT CIRCUIT WITH GROUND IN CLINOMETER SYSTEM 653
LC-19 F-32 IS DISPLAYED: SHORT CIRCUIT WITH CLINOMETER SYSTEM POWER SOURCE 654
LC-20 F-18 IS DISPLAYED: DISCONNECTION IN BATTERY CHARGE SIGNAL 655
TROUBLESHOOTING OF ABS/ASR SYSTEM 656
FLOWCHART OF TROUBLESHOOTING 657
WHEN ONLY ABS IS INSTALLED 657
WHEN ABS AND ASR ARE INSTALLED 658
METHOD OF DELETING TROUBLE DATA OF ECU 659
PROCEDURE FOR DELETING TEOUBLE DATA 659
METHOD OF TROUBLESHOOTING USING SELF-DIAGNOSTIC FUNCTION OF ECU 660
INDEX (TROUBLESHOOTING CODE) 661
SYSTEM CHECK SHEET FOR SYSTEM CHECKER 663
TROUBLESHOOTING 671
W-1 WARNING LAMP DOES NOT LIGHT UP 671
I-1 ASR INFORMATION LAMP DOES NOT GO OFF 672
ASR-1 TROUBLE IN ASR CONTROL VALVE (FOR ONLY MACHINE WITH ABS AND ASR) 673
ASR-2 674
ABS-1 TROUBLE IN ECU 675
ABS-2 TROUBLE IN RIGHT FRONT PRESSURE CONTROL VALVE 676
ABS-3 TROUBLE IN LEFT FRONT PRESSURE CONTROL VALVE 677
ABS-4 TROUBLE IN LEFT REAR PRESSURE CONTROL VALVE 678
ABS-5 TROUBLE IN RIGHT REAR PRESSURE CONTROL VALVE 679
ABS-6 TROUBLE IN RIGHT FRONT WHEEL SPEED SENSOR 680
ABS-10 ABNORMALITY IN RIGHT FRONT WHEEL SPEED SENSOR OUTPUT 680
ABS-7 TROUBLE IN LEFT FRONT WHEEL SPEED SENSOR 681
ABS-11 ABNORMALITY IN LEFT FRONT WHEEL SPEED SENSOR OUTPUT 681
ABS-8 TROUBLE IN LEFT REAR WHEEL SPEED SENSOR 682
ABS-12 ABNORMALITY IN LEFT REAR WHEEL SPEED SENSOR OUTPUT 682
ABS-9 TROUBLE IN RIGHT REAR WHEEL SPEED SENSOR 683
ABS-13 ABNORMALITY IN RIGHT REAR WHEEL SPEED SENSOR OUTPUT 683
ABS-14 TROUBLE IN VALVE RELAY (VR2) 684
ABS-15 TROUBLE IN VALVE RELAY (VR1) 685
ABS-16 TROUBLE IN VALVE RELAY (VR2) 686
ABS-17 TROUBLE IN VALVE RELAY (VR1) 687
ABS-18 ABNORMALITY IN SOURCE VOLTAGE 688
TROUBLESHOOTING OF ARSC [AUTOMATIC RETARDER SPEED CONTROLLER] SYSTEM (R NODE) 689
OUTLINE 690
ELECTRCAL CIRCUIT DIAGRAM FOR ARSC (AUTOMATIC RETADER SPEED CONTROLLER) SYSTEM 693
R-1 0 1 (ABNORMALITY IN POWER SOURCE VOLTAGE) IS DISPLAYED 695
R-2 1 0 (DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED 696
R-3 1 3 (DISCONNECTION IN TRANSMISSION OUTPUT SHAFT SPEED SENSOR SYSTEM) IS DISPLAYED 697
R-4 1 5 (FAILURE IN RETARDER OIL TEMPERATURE SENSOR SYSTEM) IS DISPLAYED 698
R-5 1 7 (FAILURE IN ACCELERATOR SIGNAL SYSTEM) IS DISPLAYED 699
R-6 1 8 (FAILURE IN SUSPENSION PRESSURE SENSOR “LEFT” SYSTEM) IS DISPLAYED 700
R-7 1 9 (FAILURE IN SUSPENSION PRESSURE SENSOR “RIGHT” SYSTEM) IS DISPLAYED 701
R-8 4 2 (DISCONNECTION IN EXHAUST BRAKE SELECTOR SIGNAL SYSTEM) IS DISPLAYED 702
R-9 4 3 (DISCONNECTION IN ARSC CAUTION LAMP SYSTEM) IS DISPLAYED 703
R-10 4 4 (DISCONNECTION IN READY LAMP SYSTEM) IS DISPLAYED 704
R-11 4 5 (DISCONNECTOIN IN PANEL CAUTION AND BUZZER SYSTEM) IS DISPLAYED 705
R-12 5 2 (SHORT CIRCUIT WITH GROUND IN EXHAUST BRAKE SELECTOR SIGNAL OUTPUT SYSTEM) IS DISPLAYED 706
R-13 5 3 (SHORT CIRCUIT WITH GROUND IN ARSC CAUTION LAMP SYSTEM) IS DISPLAYED 707
R-14 5 4 (SHORT CIRCUIT WITH GROUND IN READY OUTPUT CIRCUIT SYSTEM) IS DISPLAYED 708
R-15 5 5 (SHORT CIRCUIT WITH GROUND IN PANEL CAUTION LAMP AND BUZZER OUTPUT SYSTEM) IS DISPLAYED 709
R-16 6 0 (FAILURE IN ENGINE SPEED SYSTEM) IS DISPLAYED 710
R-17 7 0 (DISCONNECTION IN TRAVEL SPEED DISPLAY UP OUTPUT SYSTEM) IS DISPLAYED 711
R-18 7 1 (DISCONNECTION IN TRAVEL SPEED DISPLAY DOWN OUTPUT SYSTEM) IS DISPLAYED 712
R-19 7 2 (DISCONNECTION IN TRAVEL SPEED DISPLAY CLEAR OUTPUT SYSTEM) IS DISPLAYED 713
R-20 7 3 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY UP OUTPUT SYSTEM) IS DISPLAYED 714
R-21 7 4 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY DOWN OUTPUT SYSTEM) IS DISPLAYED 715
R-22 7 5 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY CLEAR OUTPUT SYSTEM)IS DISPLAYED 716
R-23 8 1 (SHORT CIRCUIT WITH GROUND IN PRESSURE CONTROL VALVE SYSTEM) IS DISPLAYED 717
R-24 8 3 (DISCONNECTION IN PRESSURE CONTROL VALVE SYSTEM) IS DISPLAYED 718
R-25 8 5 (FAILURE IN PRESSURE CONTEOL VALVE [PRESSURE CONTROL VALVE REMAINS OPEN) IS DISPLAYED 719
R-26 8 7 (FAILURE IN PRESSURE CONTROL VALVE(PRESSURE CONTROL VALVE DOES NOT OPEN) IS DISPLAYED 720
R-27 8 9 (SHORT CIRCUIT WITH GROUND IN PRESSURE SWITCH VALVE SYSTEM) IS DISPLAYED 721
R-28 9 0 (DISCONNECTION IN PRESSURE SWITCH VALVE SYSTEM) IS DISPLAYED 722
R-29 9 1 (FAILURE IN PRESSURE SWITCH VALVE SYSTEM (REMAINS OPEN)) IS DISPLAYED 723
R-30 9 2 (FAILURE IN PRESSURE SWITCH VALVE SYSTEM (DOES NOT OPEN)) IS DISPLAYED 724
R-31 9 3 (DISCONNECTION IN SYSTEM SWITCH SYSTEM) IS DISPLAYED 725
R-32 9 4 (SHORT CIRCUIT WITH GROUND IN SYSTEM SWITCH SYSTEM) IS DISPLAYED 726
R-33 9 5 (DISCONNECTION, SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED SETTING SWITCH SYSTEM) IS DISPLAYED 727
R-101 SET SPEED CANNOT BE SET 728
R-102 FAILURE CODE IS ALWAYS CLEARED (CONTROLLER DISPLAY WINDOW ALWAYS SHOWS “–“) OR FAILURE CODE CANNOT BE CLEARED 731
R-103 EFFECT OF RETARDER IS TOO STRONG WHEN MACHINE IN EMPTY, OR TOO WEAK WHEN MACHINE IS LOADED (DOES NOT JUDGE LOADED/UNLOADED CONDITION PROPERLY) 732
R-105 WHEN TRAVELING DOWNHILL, EVEN WHEN SET SPEED IS EXCEEDED, NO CONTROL IS CARRLED OUT 733
R-106 MONITOR LAMP (BUZZER) STAYS ON (OR OFF) 734
R-107 READY LAMP DOES NOT LIGHT UP (OR STAYS LIGHTED UP) 735
R-108 EXHAUST BRAKE DOES NOT WORK PROPERLY (EXHAUST BRAKE IS ACTUATED WHEN EXHAUST BRAKE SWITCH IS OFF; OR EXHAUST BRAKE IS NOT ACTUATED WHEN EXHAUST BRAKE SWITCH IS ON) 737
R-109 THERE IS DIFFERENCE BETWEEN TRAVEL SPEED ROD VALUE AND ACTUAL MACHINE VALUE 739
R-110 RETARDER LAMP DOES NOT LIGHT UP, OR STAYS LIGHTED UP 741
R-111 TRAVEL SPEED DISPLAY ALWAYS GIVES DISPLAY (OR DOES NOT GIVE ANY DISPLAY) 742
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 743
H-1 MACHINE DOES NOT START 744
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE JERKS) 746
H-3 LOCK-UP CLUTCH CANNOT BE DISENGAGED (ENGINE STALLS) 746
H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING 747
H-5 TRANSMISSION DOES NOT SHIFT UP 747
H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING 748
H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR 752
H-8 TORQUE CONVERTAR OIL TEMPERATURE IS HIGH 754
H-9 TORQUE CONVERTER OIL PRESSURE IS LOW 755
H-10 FRONT BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE 756
H-11 REAR BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE 757
H-12 STEERING WHEEL IS HEAVY 758
H-13 STEERING WHEEL DOES NOT WORK 759
H-14 STEERING WHEEL VIBRATES 759
H-15 HOIST CYLINDER LACKS LIFTING FORCE (LIFTING SPEED) 760
H-16 HOIST CYLINDER DOES NOT WORK 761
H-17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY 762
H-18 AIR PRESSURE DOES NOT RISE (LOW-PRESSURE BUZZER DOES NOT STOP, AIR GAUGE DOES NOT RISE TO GREEN RANGE) 763
TROUBLESHOOTING OF MONITOR PANEL SYSTEM (P MODE) 764
METHOD OF SELF-DIAGNOSTIC DISPLAY FOR MONITOR PANEL AND CONTROLLERS 766
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE 767
ELECTRICAL CIRCUIT DIAGRAM FOR MONITOR PANEL SYSTEM 771
P-1 CHECK PATTERN FOR WIRING HARNESSES BETWEEN MODULES 773
P-2 NOTHING ON MONITOR PANAL WORKS 777
P-3 LH, RH MODULE AND FUEL GAUGE DO NOT WORK 778
P-4 LH, RH MODULE AND FUEL GAUGE DO NOT WORK 779
P-5 RH MODULE DOES NOT WORK 780
P-6 LH MODULE DOES NOT WORK 781
P-7 TRAVEL CALCULATOR DOES NOT WORK 782
P-8 SERVICE METER DISPLAY DOES NOT WORK CORRECTLY 783
P-9 CENTRAL WARNING LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS FAILURE CODE (MONITOR PANEL DISPLAY) [A002] 784
P-10 CENTRAL WARNING LAMP STAYS LIGHTED UP 785
P-11 ALARM BUZZER DOES NOT WORK, OR MONITOR PANEL DETECTS FAILURE CODE [A003] 786
P-12 ALARM BUZZER CONTINUES TO SOUND 787
P-13 ALL DATA FROM SHIFT CONTROLLER (SPEEDOMETER, TACHOMETER, SHIFT INDICATOR, ETC ) ARE ABNORMAL (NOTHING IS DISPLAYED, OR DISPLAY DOES NOT CHANGE), OR MONITOR PANEL DETECTS SERVICE CODE [A013] OR MONITOR PANEL DETECTS SERVICE CODE [A018] 788
P-14 SUSPENSION MODE, POWER/ECONOMY MODE DISPLAY ARE ABNORMAL (NOTHING IS DISPLAYED, OR DISPLAY DOES NOT CHANGE), OR MONITOR PANEL DETECTS SERVICE CODE [A016] 789
P-15 GAUGE DISPLAYS ARE ABNORMAL (NOTHING IS DISPLAYED, OR DISPLY DOES NOT CHANGE) 790
P-16 COOLING WATER LEVEL DROP CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001] 791
P-17 COOLING WATER LEVAL DROP CAUTION LAMP STAYS LIGHTED UP 792
P-18 EMERGENCY STEERING PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001] 793
P-19 EMERGENCY STEERING PILOT LAMP STAYS LIGHTED UP 794
P-20 ENGINE OIL PRESSURE DROP CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001] 795
P-21 ENGINE OIL PRESSURE DROP CAUTION LAMP STAYS LIGHTED UP 796
P-22 EXHAUST BRAKE PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001] 797
P-23 EXHAUST BRAKE PILOT LAMP STAYS LIGHTED UP 798
P-24 CHARGING CIRCUIT ABNORMALITY CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001] 799
P-25 CHARGING CIRCUIT ABNORMALITY CAUTION LAMP STAYS LIGHTED UP 800
P-26 TRANSMISSION FILTER CLOGGING CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001] 801
P-27 TRANSMISSION FILTER CLOGGING CAUTION LAMP STAYS LIGHTED UP 802
P-28 BRAKE STROKE CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001] 803
P-29 BRAKE STROKE CAUTION LAMP STAYS LIGHTED UP 804
P-30 PREHEATING SWITCH PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001] 805
P-31 PREHEATING SWITCH PILOT LAMP STAYS LIGHTED UP 806
P-32 TILT WARNING LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001] 807
P-33 TILT WARNING LAMP STAYS LIGHTED UP 808
P-34 BODY FLOAT (EXCEPT FLOAT) PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001] 809
P-35 BODY FLOAT (EXCEPT FLOAT) PILOT LAMP STAYS LIGHTED UP 810
P-36 REAR BRAKE PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001] 811
P-37 REAR BRAKE PILOT LAMP STAYS LIGHTED UP 812
P-38 PARKING BRAKE PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001] 813
P-39 PARKING BRAKE PILOT LAMP STAYS LIGHTED UP 814
P-40 MAINTENANCE CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001] 815
P-41 MAINTENANCE CAUTION LAMP STAYS LIGHTED UP 816
P-42 STEERING OIL TEMPERATURE CAUTION LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001] 817
P-43 STEERING OIL TEMPERATURE CAUTION LAMP STAYS LIGHTED UP 818
P-44 DIFFERENTIAL LOCK PILOT LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001] 819
P-45 DIFFERENTIAL LOCK PILOT LAMP STAYS LIGHTED UP 820
P-46 HIGH BEAM DISPLAY DOES NOT LIGHT UP 821
P-47 TURN SIGNAL LAMP (RIGHT) DOES NOT LIGHT UP 823
P-48 TURN SIGNAL LAMP (LEFT) DOES NOT LIGHT UP 824
P-49 LAMP CHECK SWITCH DOES NOT WORK 825
P-50 AISS SWITCH DOES NOT WORK 826
P-51 EXHAUST BRAKE SWITCH DOES NOT WORK 827
P-52 MODE CHANGE SWITCH (1) DOES NOT WORK 828
P-53 MODE CHANGE SWITCH (2) DOES NOT WORK 829
P-54 KPH/MPH SPEEDOMETER UNIT SELECTOR DOES NOT WORK 830
P-55 DEFECTIVE OPERATION OF ALL SWITCH INPUTS 831
P-56 MONITOR PANEL DETECTS SERVICE CODES [A014] OR [A019] 832
P-57 MONITOR PANEL DETECTS SERVICE CODE [A015] 833
P-58 MONITOR PANEL DETECTS SERVICE CODE [A011] 834
P-59 MONITOR PANEL DETECTS SERVICE CODE [A012] 834
P-60 MONITOR PANEL DETECTS SERVICE CODE [A000] 834
VHMS MACHINE HEALTH DIAGNOSIS SYSTEM (OPT) 835
1 BASIC PRECAUTIONS 836
1-1 OPERAION, SAFETY, INSPECITON AND MAINTENANCE OF MACHINE 836
1-2 OPERATION OF MONITORING SYSTEM 836
1-3 CONSTANT POWER SUPPLY (BATERY DIRECT POWER SUPPLY) 836
1-4 PRECAUTIONS AT THE TIME OF TURNING ON THE POWER FOR VHMS 837
1-5 PRECAUTIONS AT THE TIME OF REPLACING VHMS AND TRANSMISSION CONTROLLER 837
1-6 OPERATION OF COMMUNICATION (ORB ORB COMMUNICATION) CONTROLLER 838
2 OVERVIEW 839
2-1 APPLICABLE MODEL 839
2-2 BASIC CONFIGURATION 839
2-3 INSTALLATION DRAWING 842
3 STRUCTURE AND FUNCTION 844
3-1 VHMS CONTROLLER 844
3-2 BLOW-BY GAS SENSOR 844
3-3 ENGINE OIL TEMPERAUTRE SENSOR 845
3-4 AMPLIFIER FOR EXHAUST GAS TEMPERATURE SENSOR 846
3-5 COMMUNICATION (ORB ORB COMMUNICATION) CONTROLLER/ANTENNA 847
4 TROUBLESHOOTING 848
4-1 TROUBLESHOOTING EQUIPMENT LIST 848
4-2 CONNECTOR TYPES AND MOUNTING LOCATIONS 849
4-3 CONNECTOR ARRANGEMENT DIAGRAM 850
4-4 VHMS RELATED ELECTRICAL CIRCUIT DIAGRAM 855
4-5 ERROR CODE LIST 857
4-6 STANDARD VALUE TABLE FOR ELECTRICAL PARTS 858
4-7 TROUBLE PHENOMENA LIST 859
HM-1: ABNORMALITY IN SATELLITE DATA TRANSMISSION 861
HM-2: ABNORMALITY IN DOWNLOADING OR SETTING WITH THE PC 862
HM-3: MANUAL SNAP HAS NOT BEEN RECORDED 863
HM-4: ABNORMAL BLOW-BY GAS PRESSURE 864
HM-5: ABNORMAL EXHAUST GAS TEMPERATURE 865
HM-6: ABNORMAL ENGINE OIL TEMPERATURE 866
HM-7: ABNORMAL ENGINE OIL PRESSURE 867
HM-8: ABNORMAL ENGINE SPEED 868
HM-9: ABNORMAL FUEL INJECTION AMOUNT 869
HM-10: T/M DATE IS NOT DISPLAYED 870
HM-11: WHILE TRAVELLING, TRAVEL VALVE SUDDENLY BECOMES NEUTRAL AND CANNOT TRAVEL 870
5 SETTING OF VHMS CONTROLLER 871
5-1 SETTING OF VHMS CONTROLLER 871
5-2 SETTING ITEM 871
5-3 SETTING FLOW (OUTLINE) 871
5-4 CHECK OF OPERATION AND PERFORMANCE 872
5-5 DATA COLLECTION 872
6 DATA RECOVERY AND TRANSMISSION 873
6-1 DATA RECOVERY 873
7 INSPECTION AND MAINTENANCE 880
7-1 INSPECTION TIMING: INSPECTION AND MAINTENANCE TIMING OF MACHINE 880
7-2 INSPECTION ITEM 880
7-3 CORRECTIVE ACTION 880
8 REPLACEMENT OF PARTS 880
8-1 IF INITIAL SET-UP OF VHMS SYSTEM HAS BEEN MADE OR VHMS CONTROLLER HAS BEEN REPLACED 880
8-2 WHEN COMMUNICATION CONTROLLER IS REPLACED 880
PROCEDURE Ⅰ FOR INITIAL SETUP OF VHMS 881
PROCEDURE Ⅱ FOR OPENING ORBCOMM SERVICE 883
30 DISASSEMBLY AND ASSEMBLY 887
METHOD OF USING MANUAL 889
PRECAUTIONS WHEN CARRYING OUT OPERATION 890
SPECIAL TOOL LIST 892
STARTING MOTOR 895
REMOVAL AND INSTALLATION 895
ALTERNATOR 896
REMOVAL AND INSTALLATION 896
ENGINE OIL COOLER 897
REMOVAL AND INSTALLATION 897
AIR CONDITIONER COMPERSSOR 898
REMOVAL AND INSTALLATION 898
FUEL INJECTION PUMP 899
REMOVAL 899
INSTALLATION 900
AIR COMPRESSOR 901
REMOVAL AND INSTALLATION 901
AIR CONDITIONER COMPERSSOR 902
REMOVAL AND INSTALLATION 902
WATER PUMP 903
REMOVAL AND INSTALLATION 903
AFTERCOOLER CORE 904
REMOVAL AND INSTALLATION 904
EXHAUST BRAKE CYLINDER 905
REMOVAL AND INSTALLATION 905
TURBOCHARGER 906
REMOVAL AND INSTALLATION 906
NOZZLE HOLDER 907
REMOVAL AND INSTALLATION 907
CYLINDER HEAD 908
REMOVAL 908
INSTALLATION 911
ENGINE 912
REMOVAL 912
INSTALLATION 915
ENGINE FRONT SEAL 916
REMOVAL AND INSTALLATION 916
ENGINE REAR SEAL 918
REMOVAL AND INSTALLATION 918
RADIATOR, TORQUE CONVERTER COOLER 920
REMOVAL 920
INSTALLTION 922
BRAKE OIL COOLER 923
REMOVAL AND INSTALLATION 923
OUTPUT SHAFT 924
REMOVAL AND INSTALLATION 924
DISASSEMBLY 926
ASSEMBLY 927
TORQUE CONVERTER, TRANSMISSION 929
REMOVAL 929
INSTALLATION 930
PROCEDURE FOR CENTERING THE ENGINE ASSEMBLY AND TROQUE CONVERTER, TRANSMISSION ASSEMBLY 931
TORQUE CONVERTER, CONTROL VALVE 932
REMOVAL AND INSTALLATION 932
DISASSEMBLY AND ASSEMBLY 933
TORQUE CONVERTER AND TRANSMISSION 934
DISCONNECTION 934
CONNECTION 935
TORQUE CONVERTER, PTO 936
DISASSEMBLY 936
ASSEMBLY 942
TRANSMISSION 949
DISASSEMBLY 949
ASSEMBLY 965
TRANSMISSION CONTROL VALVE (ECMV ASSEMBLY) 982
REMOVAL AND INSTALLATION 982
ECMV 983
DISASSEMBLY AND ASSEMBLY 983
DIFFERENTIAL 985
REMOVAL AND INSTALLATION 985
DISASSEMBLY 986
ASSEMBLY 990
FRONT WHEEL 999
REMOVAL AND INSTALLATION 999
REAR WHEEL 1000
REMOVAL 1000
INSTALLATION 1001
FRONT BRAKE CALIPER PAD 1002
REMOVAL AND INSTALLATION 1002
FRONT BRAKE CALIPER 1003
REMOVAL AND INSTALLATION 1003
DISASSEMBLY 1004
ASSEMBLY 1005
FRONT WHEEL HUB 1007
DISASSEMBLY 1007
ASSEMBLY 1009
FINAL DRIVE CARRIER 1012
REMOVAL AND INSTALLATION 1012
DISASSEMBLY AND ASSEMBLY 1013
FIANL DRIVE 1014
DISASSEMBLY 1014
ASSEMBLY 1016
REAR BRAKE 1018
REMOVAL AND INSTALLATION 1018
DISASSEMBLY 1019
ASSEMBLY 1020
PARKING BRAKE PAD 1022
REMOVAL 1022
INSTALLATION 1023
PARKING BRAKE CALIPER 1025
REMOVAL AND INSTALLATION 1025
DISASSEMBLY AND ASSEMBLY 1026
FRONT SUSPENSION CYLINDER 1027
REMOVAL AND INSTALLATION 1027
DISASSEMBLY 1029
ASSEMBLY 1030
VARIABLE DAMPING SELECTOR VALVE 1031
DISASSEMBLY 1031
ASSEMBLY 1032
REAR SUSPENSION CYLINDER 1033
REMOVAL AND INSTALLATION 1033
DISASSEMBLY 1034
ASSEMBLY 1035
AIR GOVERNOR 1036
REMOVAL AND INSTALLATION 1036
DISASSEMBLY AND ASSEMBLY 1037
BRAKE VALVE 1038
REMOVAL AND INSTALLATION 1038
DISASSEMBLY 1039
ASSEMBLY 1041
PARKING BRAKE CHAMBER 1043
REMOVAL AND INSTALLATION 1043
DISASSEMBLY 1044
ASSEMBLY 1045
FRONT BRAKE CHAMBER 1047
REMOVAL AND INSTALLATION 1047
DISASSEMBLY 1048
ASSEMBLY 1050
REAR BRAKE CHAMBER 1047
REMOVAL AND INSTALLATION 1047
DISASSEMBLY 1052
ASSEMBLY 1055
SLACK ADJUSTER 1058
REMOVAL AND INSTALLATION 1058
DISASSEMBLY AND ASSEMBLY 1059
AIR DRIER (DESICCANT TYPE) 1060
REMOVAL AND INSTALLATION 1060
DISASSEMBLY AND ASSEMBLY 1061
TRANSMISSION LUBRICATION, RETARDER BRAKE PUMP 1078
REMOVAL AND INSTALLATION 1078
BRAKE COOLING PUMP 1079
REMOVAL AND INSTALLATION 1079
HOIST, STEERING PUMP 1079
REMOVAL AND INSTALLATION 1079
EMERGENCY STEERING MOTOR PUMP 1080
REMOVAL AND INSTALLATION 1080
BRAKE CONTROL VALVE 1081
REMOVAL AND INSTALLATION 1081
STEERING VALVE 1082
REMOVAL AND INSTALLATION 1082
DISASSEMBLY 1083
ASSEMBLY 1087
DEMAND VALVE 1094
REMOVAL AND INSTALLATION 1094
DISASSEMBLY AND ASSEMBLY 1095
RELIEF VALVE 1096
DISASSEMBLY AND ASSEMBLY 1096
HOIST VALVE 1097
REMOVAL AND INSTALLATION 1097
DISASSEMBLY 1098
ASSEMBLY 1099
STEERING CYLINDER 1100
REMOVAL AND INSTALLATION 1100
DISASSEMBLY 1101
ASSEMBLY 1103
HOIST CYLINDER 1105
REMOVAL AND INSTALLATION 1105
DISASSEMBLY 1106
ASSEMBLY 1107
BODY 1108
REMOVAL 1108
INSTALLATION 1109
TRANSMISSION CONTROLLER 1110
REMOVAL AND INSTALLATION 1110
SUSPENSION CONTROLLER 1110
REMOVAL AND INSTALLATION 1110
40 MAINTENANCE STANDARD 1111
OUTPUT SHAFT 1112
TURQUE CONVERTER VALVE 1113
TORQUE CONVERTER 1114
TRANSMISSION 1116
ECMV 1120
FRONT AXLE 1121
REAR AXLE SUPPORT 1122
DIFFERENTIAL 1123
FINAL DRIVE 1124
FRONT BRAKE 1125
REAR BRAKE 1126
PARKING BRAKE 1127
STEERING LINKAGE 1128
FRONT SUSPENSION CYLINDER 1130
REAR SUSPENSION CYLINDER 1131
PARKING BRAKE CHAMBER 1132
SLACK ADJUSTER 1133
HYDRAULIC PUMP 1134
DEMAND VALVE 1137
CROSS-OVER RELIEF VALVE 1137
HOIST VALVE 1138
STEERING CYLINDER 1139
HOIST CYLINDER 1140
90 OTHERS 1141
ELECTRICAL CIRCUIT DIAGRAM 1142
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (1/3) 1142
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (2/3) 1143
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (3/3) 1144
ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (1/2) 1145
ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (2/2) 1146
ELECTRICAL CONTROL SYSTEM 1147
ELECTRICAL CIRCUIT DIAGRAM 1147
AUTOMATIC RETARD SPEED CONTROL SYSTEM 1148
ELECTRICAL CIRCUIT DIAGRAM 1148
AUTOMATIC SHIFT CONTROL SYSTEM 1149
ELECTRICAL CIRCUIT DIAGRAM 1149
AUTOMATIC SUSPENSION SYSTEM 1150
SYSTEM CIRCUIT DIAGRAM (1/2) 1150
SYSTEM CIRCUIT DIAGRAM (2/2) 1151
PAYLOAD METER (PRINTER TYPE) 1152
ELECTRICAL CIRCUIT DIAGRAM 1152
PAYLOAD METER Ⅱ (CARD TYPE) 1153
ELECTRICAL CIRCUIT DIAGRAM 1153
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM 1154
VHMS MACHINE HEALTH DIAGNOSIS SYSTEM (OPT) 1155
1 BASIC PRECAUTIONS 1156
1-1 OPERAION, SAFETY, INSPECITON AND MAINTENANCE OF MACHINE 1156
1-2 OPERATION OF MONITORING SYSTEM 1156
1-3 CONSTANT POWER SUPPLY (BATERY DIRECT POWER SUPPLY) 1156
1-4 PRECAUTIONS AT THE TIME OF TURNING ON THE POWER FOR VHMS 1157
1-5 PRECAUTIONS AT THE TIME OF REPLACING VHMS AND TRANSMISSION CONTROLLER 1157
1-6 OPERATION OF COMMUNICATION (ORB ORB COMMUNICATION) CONTROLLER 1158
2 OVERVIEW 1159
2-1 APPLICABLE MODEL 1159
2-2 BASIC CONFIGURATION 1159
2-3 INSTALLATION DRAWING 1162
3 STRUCTURE AND FUNCTION 1164
3-1 VHMS CONTROLLER 1164
3-2 BLOW-BY GAS SENSOR 1164
3-3 ENGINE OIL TEMPERAUTRE SENSOR 1165
3-4 AMPLIFIER FOR EXHAUST GAS TEMPERATURE SENSOR 1166
3-5 COMMUNICATION (ORB ORB COMMUNICATION) CONTROLLER/ANTENNA 1167
4 TROUBLESHOOTING 1168
4-1 TROUBLESHOOTING EQUIPMENT LIST 1168
4-2 CONNECTOR TYPES AND MOUNTING LOCATIONS 1169
4-3 CONNECTOR ARRANGEMENT DIAGRAM 1170
4-4 VHMS RELATED ELECTRICAL CIRCUIT DIAGRAM 1175
4-5 ERROR CODE LIST 1177
4-6 STANDARD VALUE TABLE FOR ELECTRICAL PARTS 1178
4-7 TROUBLE PHENOMENA LIST 1179
HM-1: ABNORMALITY IN SATELLITE DATA TRANSMISSION 1181
HM-2: ABNORMALITY IN DOWNLOADING OR SETTING WITH THE PC 1182
HM-3: MANUAL SNAP HAS NOT BEEN RECORDED 1183
HM-4: ABNORMAL BLOW-BY GAS PRESSURE 1184
HM-5: ABNORMAL EXHAUST GAS TEMPERATURE 1185
HM-6: ABNORMAL ENGINE OIL TEMPERATURE 1186
HM-7: ABNORMAL ENGINE OIL PRESSURE 1187
HM-8: ABNORMAL ENGINE SPEED 1188
HM-9: ABNORMAL FUEL INJECTION AMOUNT 1189
HM-10: T/M DATE IS NOT DISPLAYED 1190
HM-11: WHILE TRAVELLING, TRAVEL VALVE SUDDENLY BECOMES NEUTRAL AND CANNOT TRAVEL 1190
5 SETTING OF VHMS CONTROLLER 1191
5-1 SETTING OF VHMS CONTROLLER 1191
5-2 SETTING ITEM 1191
5-3 SETTING FLOW (OUTLINE) 1191
5-4 CHECK OF OPERATION AND PERFORMANCE 1192
5-5 DATA COLLECTION 1192
6 DATA RECOVERY AND TRANSMISSION 1193
6-1 DATA RECOVERY 1193
7 INSPECTION AND MAINTENANCE 1200
7-1 INSPECTION TIMING: INSPECTION AND MAINTENANCE TIMING OF MACHINE 1200
7-2 INSPECTION ITEM 1200
7-3 CORRECTIVE ACTION 1200
8 REPLACEMENT OF PARTS 1200
8-1 IF INITIAL SET-UP OF VHMS SYSTEM HAS BEEN MADE OR VHMS CONTROLLER HAS BEEN REPLACED 1200
8-2 WHEN COMMUNICATION CONTROLLER IS REPLACED 1200
PROCEDURE Ⅰ FOR INITIAL SETUP OF VHMS 1201
PROCEDURE Ⅱ FOR OPENING ORBCOMM SERVICE 1203

DESCRIPTION:

Komatsu HD465-5 HD605-5 Dump Truck Shop Manual SEBM015209 – PDF DOWNLOAD 

MACHINE MODEL   SERIAL NUMBER
HD465-5                    4626 and up
HD605-5                    1013 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 29/12/24