Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
KOMATSU HD785-5 HD985-5 SHOP MANUAL SEBM013916 – PDF DOWNLOAD
$38.95
KOMATSU HD785-5 HD985-5 SHOP MANUAL SEBM013916 – PDF DOWNLOAD
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
KOMATSU HD785-5 HD985-5 SHOP MANUAL SEBM013916 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU HD785-5 HD985-5 SHOP MANUAL SEBM013916 – PDF DOWNLOAD
Language : English
Pages : 1385
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU HD785-5 HD985-5 SHOP MANUAL SEBM013916 – PDF DOWNLOAD
COVER............................................................................................................................................................................................................................................................................. 1
CONTENTS.......................................................................................................................................................................................................................................................................... 2
01 GENERAL........................................................................................................................................................................................................................................................................ 29
GENERAL ASSEMBLY DRAWING...................................................................................................................................................................................................................................................... 30
SPECIFICATIONS................................................................................................................................................................................................................................................................ 32
WEIGHT TABLE.................................................................................................................................................................................................................................................................. 35
LIST OF LUBRICANT AND COOLANT................................................................................................................................................................................................................................................. 36
10 STRUCTURE AND FUNCTION......................................................................................................................................................................................................................................................... 37
RADIATOR, TORQUE CONVERTER COOLER............................................................................................................................................................................................................................................. 40
BRAKE OIL COOLER.............................................................................................................................................................................................................................................................. 41
POWER TRAIN SKELETON.......................................................................................................................................................................................................................................................... 42
OUTPUT SHAFT (HD785-5)........................................................................................................................................................................................................................................................ 43
OUTPUT SHAFT (HD985-5)........................................................................................................................................................................................................................................................ 44
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING............................................................................................................................................................................................................................ 45
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM................................................................................................................................................................................................................... 46
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT SCHEMATICS................................................................................................................................................................................................................ 47
TORQUE CONVERTER.............................................................................................................................................................................................................................................................. 48
TORQUE CONVERTER VLAVE........................................................................................................................................................................................................................................................ 50
LOCKUP SOLENOID VALVE......................................................................................................................................................................................................................................................... 54
TRANSMISSION.................................................................................................................................................................................................................................................................. 55
TRANSMISSION VALVE............................................................................................................................................................................................................................................................ 58
ECMV.......................................................................................................................................................................................................................................................................... 59
LUBRICATION RELIEF VALVE...................................................................................................................................................................................................................................................... 64
FRONT AXLE (HD785-5).......................................................................................................................................................................................................................................................... 65
FRONT AXLE (HD985-5).......................................................................................................................................................................................................................................................... 66
REAR AXLE (HD785-5)........................................................................................................................................................................................................................................................... 68
REAR AXLE (HD985-5)........................................................................................................................................................................................................................................................... 71
DIFFERENTIAL.................................................................................................................................................................................................................................................................. 72
DIFFERENTIAL LOCK CONTROL..................................................................................................................................................................................................................................................... 74
DIFFERENTIAL LOCK SOLENOID VALVE.............................................................................................................................................................................................................................................. 76
FINAL DRIVE (HD785-5)......................................................................................................................................................................................................................................................... 77
FINAL DRIVE (HD985-5)......................................................................................................................................................................................................................................................... 79
FRONT BRAKE................................................................................................................................................................................................................................................................... 80
REAR BRAKE.................................................................................................................................................................................................................................................................... 81
PARKING BRAKE................................................................................................................................................................................................................................................................. 85
WHEELS (HD785-5).............................................................................................................................................................................................................................................................. 86
WHEELS (HD985-5).............................................................................................................................................................................................................................................................. 87
AXLE SUPPORT (HD785-5)........................................................................................................................................................................................................................................................ 88
AXLE SUPPORT (HD985-5)........................................................................................................................................................................................................................................................ 89
STEERING SYSTEM............................................................................................................................................................................................................................................................... 90
STEERING WHEEL (HD785-5)...................................................................................................................................................................................................................................................... 91
STEERING WHEEL (HD985-5)...................................................................................................................................................................................................................................................... 92
STEERING LINKAGE.............................................................................................................................................................................................................................................................. 93
SUSPENSION SYSTEM............................................................................................................................................................................................................................................................. 95
SUSPENSION CYLINDER........................................................................................................................................................................................................................................................... 97
REAR SUSPENSION CYLINDER...................................................................................................................................................................................................................................................... 100
AIR PIPING.................................................................................................................................................................................................................................................................... 102
AIR CIRCUIT DIAGRAM........................................................................................................................................................................................................................................................... 104
DESICCANT TYPE AIR DRIER (IF EQUIPPED)........................................................................................................................................................................................................................................ 106
AIR GOVERNOR.................................................................................................................................................................................................................................................................. 107
SAFETY VALVE.................................................................................................................................................................................................................................................................. 107
CHECK VALVE................................................................................................................................................................................................................................................................... 108
DOUBLE CHECK VALVE............................................................................................................................................................................................................................................................ 108
AUTO DRAIN VALVE.............................................................................................................................................................................................................................................................. 109
HAND BRAKE VALVE.............................................................................................................................................................................................................................................................. 110
BRAKE VALVE................................................................................................................................................................................................................................................................... 111
EMERGENCY BRAKE CONTROL VALVE................................................................................................................................................................................................................................................. 112
PARKING BRAKE CONTROL VALVE................................................................................................................................................................................................................................................... 115
PARKING BRAKE PILOT VALVE..................................................................................................................................................................................................................................................... 116
RELAY VLAVE................................................................................................................................................................................................................................................................... 117
PARKING BRAKE RELAY VALVE..................................................................................................................................................................................................................................................... 120
QUICK-RELEASE VALVE........................................................................................................................................................................................................................................................... 122
PARKING BRAKE CHAMBER......................................................................................................................................................................................................................................................... 122
RATIO VALVE (FOR FRONT BRAKE)................................................................................................................................................................................................................................................. 123
FRONT BRAKE CHAMBER........................................................................................................................................................................................................................................................... 124
BRAKE CHAMBER................................................................................................................................................................................................................................................................. 125
SLACK ADJUSTER................................................................................................................................................................................................................................................................ 128
AIR DRIER (DESICCANT TYPE) (IF EQUIPPED)...................................................................................................................................................................................................................................... 129
HYDRAULIC PIPING.............................................................................................................................................................................................................................................................. 131
HYDRALUIC CIRCUIT DIAGRAM..................................................................................................................................................................................................................................................... 133
DUMP BODY CONTROL............................................................................................................................................................................................................................................................. 134
HYDRAULIC TANK AND BRAKE COOLING OIL TANK (HD785-5)........................................................................................................................................................................................................................... 135
HYDRAULIC TANK AND BRAKE COOLING OIL TANK (HD985-5)........................................................................................................................................................................................................................... 136
BRAKE COOLING OIL CONTROL VALVE (BCV)......................................................................................................................................................................................................................................... 137
STEERING VALVE................................................................................................................................................................................................................................................................ 138
DEMAND VALVE.................................................................................................................................................................................................................................................................. 142
HOIST VALVE................................................................................................................................................................................................................................................................... 146
CROSSOVER RELIEF VALVE........................................................................................................................................................................................................................................................ 148
STEERING CYLINDER............................................................................................................................................................................................................................................................. 149
HOIST CYLINDER................................................................................................................................................................................................................................................................ 149
ELECTRICAL CIRCUIT DIAGRAM.................................................................................................................................................................................................................................................... 150
STOP LAMP SWITCH.............................................................................................................................................................................................................................................................. 153
EXHAUST BRAKE SWITCH.......................................................................................................................................................................................................................................................... 153
TILT SWITCH................................................................................................................................................................................................................................................................... 153
FRONT BRAKE CUT-OFF VALVE..................................................................................................................................................................................................................................................... 154
OVERRUN PREVENTION VALVE...................................................................................................................................................................................................................................................... 155
EXHAUST BRAKE VALVE........................................................................................................................................................................................................................................................... 155
HORN VALVE.................................................................................................................................................................................................................................................................... 156
PARKING BRAKE SWITCH.......................................................................................................................................................................................................................................................... 156
AIR CONDITIONER............................................................................................................................................................................................................................................................... 157
PIPING DIAGRAM............................................................................................................................................................................................................................................................ 157
ELECTRICAL CIRCUIT DIAGRAM................................................................................................................................................................................................................................................ 158
REFRIGERANT CIRCUIT DIAGRAM............................................................................................................................................................................................................................................... 160
UNIT...................................................................................................................................................................................................................................................................... 161
RECEIVER DRYER............................................................................................................................................................................................................................................................ 161
CONDENSER................................................................................................................................................................................................................................................................. 162
COMPRESSOR................................................................................................................................................................................................................................................................ 162
ENGINE CONTROL SYSTEM......................................................................................................................................................................................................................................................... 163
SYSTEM DRAWING............................................................................................................................................................................................................................................................ 163
ELECTRICAL CIRCUIT DIAGRAM................................................................................................................................................................................................................................................ 165
FUEL INJECTION PUMP ELECTRIC GOVERNOR..................................................................................................................................................................................................................................... 166
HYDRAULIC CIRCUIT DIAGRAM................................................................................................................................................................................................................................................. 167
AISS...................................................................................................................................................................................................................................................................... 167
SENSOR, SWITCHES.......................................................................................................................................................................................................................................................... 168
EXHAUST BRAKE................................................................................................................................................................................................................................................................. 169
SYSTEM DIAGRAM............................................................................................................................................................................................................................................................ 169
SYSTEM DIAGRAM............................................................................................................................................................................................................................................................ 170
AUTOMATIC SHIFT CONTROL SYSTEM................................................................................................................................................................................................................................................ 172
SYSTEM DIAGRAM............................................................................................................................................................................................................................................................ 172
ELECTRICAL CIRCUIT DIAGRAM................................................................................................................................................................................................................................................ 174
TRANSMISSION CONTROLLER................................................................................................................................................................................................................................................... 175
CONNECTOR SIGNALS......................................................................................................................................................................................................................................................... 176
SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFTING RANGES.................................................................................................................................................................................................................. 177
AUTOMATIC GEAR SHIFTING LINE GRAPH........................................................................................................................................................................................................................................ 178
SHIFT LEVER SWITCH........................................................................................................................................................................................................................................................ 180
SENSORS, SWITCHES......................................................................................................................................................................................................................................................... 181
TRANSMISSION OIL TEMPERATURE SENSOR....................................................................................................................................................................................................................................... 181
FILL SWITCH............................................................................................................................................................................................................................................................... 182
ACCELERATOR SENSOR........................................................................................................................................................................................................................................................ 183
SHIFT LIMIT SWITCH........................................................................................................................................................................................................................................................ 184
MODE SELECTOR SWITCH...................................................................................................................................................................................................................................................... 184
SELF-DIAGNOSTIC FUNCTION.................................................................................................................................................................................................................................................. 185
AUTOMATIC EMERGENCY STEERING SYSTEM........................................................................................................................................................................................................................................... 186
SYSTEM DIAGRAM............................................................................................................................................................................................................................................................ 186
ELECTRIC CIRCUIT DIAGRAM.................................................................................................................................................................................................................................................. 187
FLOW SWITCH............................................................................................................................................................................................................................................................... 188
RELAY TIMER............................................................................................................................................................................................................................................................... 190
AUTOMATIC SUSPENSION SYSTEM................................................................................................................................................................................................................................................... 191
SYSTEM DIAGRAM............................................................................................................................................................................................................................................................ 191
STRUCTURE OF SYSTEM....................................................................................................................................................................................................................................................... 192
SYSTEM CIRCUIT DIAGRAM.................................................................................................................................................................................................................................................... 193
AUTOMATIC SUSPENSION MODE SELECTION CONTROL................................................................................................................................................................................................................................... 194
SUSPENSION CONTROLLER..................................................................................................................................................................................................................................................... 195
SENSOR, SWITCHES.......................................................................................................................................................................................................................................................... 196
STEERING ANGLE SENSOR................................................................................................................................................................................................................................................. 196
PRESSURE SENSOR....................................................................................................................................................................................................................................................... 196
SELF-DIAGNOSTIC FUNCTION.................................................................................................................................................................................................................................................. 197
PAYLOAD METER (PRINTER TYPE) (OP)............................................................................................................................................................................................................................................. 198
STRUCTURE OF SYSTEM....................................................................................................................................................................................................................................................... 198
ELECTRICAL CIRCUIT DIAGRAM................................................................................................................................................................................................................................................ 199
PAYLOAD METER BLOCK DIAGRAM............................................................................................................................................................................................................................................... 199
PRINCIPLE OF CALCULATION.................................................................................................................................................................................................................................................. 200
FEATURES OF EQUIPMENT..................................................................................................................................................................................................................................................... 202
1. PAYLOAD METER...................................................................................................................................................................................................................................................... 202
2. PRESSURE SENSOR.................................................................................................................................................................................................................................................... 205
3. CLINOMETER......................................................................................................................................................................................................................................................... 206
4. LAMP DRIVE RELAY................................................................................................................................................................................................................................................... 206
SELF-DIAGNOSTIC FUNCTION.................................................................................................................................................................................................................................................. 207
PAYLOAD METER โ
ก (CARD TYPE) (OP).............................................................................................................................................................................................................................................. 208
STRUCTURE OF SYSTEM....................................................................................................................................................................................................................................................... 208
ELECTRICAL CIRCUIT DIAGRAM................................................................................................................................................................................................................................................ 209
PAYLOAD METER BLOCK DIAGRAM............................................................................................................................................................................................................................................... 209
PRINCIPLE OF MEASUREMENT.................................................................................................................................................................................................................................................. 210
FEATURE OF EACH DEVICE.................................................................................................................................................................................................................................................... 211
1. PAYLOAD METER โ
ก.................................................................................................................................................................................................................................................... 211
2. PRESSURE SENSOR.................................................................................................................................................................................................................................................... 239
3. CLINOMETER......................................................................................................................................................................................................................................................... 240
4. LAMP DRIVE RELAY................................................................................................................................................................................................................................................... 240
5. SELF-DIAGNOSTIC FUNCTION........................................................................................................................................................................................................................................... 241
MACHINE MONITOR SYSTEM........................................................................................................................................................................................................................................................ 247
SYSTEM DRAWING............................................................................................................................................................................................................................................................ 247
MONITOR PANEL DIAGRAM..................................................................................................................................................................................................................................................... 249
MACHINE MONITOR NORMAL DISPLAY FUNCTONS................................................................................................................................................................................................................................... 250
SELF-DIAGNOSTIC FUNCTION WHEN STARTING SWITCH IS OPERATED................................................................................................................................................................................................................. 257
TRAVEL SPEED COMPENSATION ROTARY SWITCH................................................................................................................................................................................................................................... 257
SENSORS, SWITCHES......................................................................................................................................................................................................................................................... 258
ENGINE SPEED SENSOR................................................................................................................................................................................................................................................... 258
TRANSMISSION SPEED SENSOR............................................................................................................................................................................................................................................. 258
ENGINE OIL PRESSURE................................................................................................................................................................................................................................................... 259
ENGINE WATER TEMPERATURE SENSOR....................................................................................................................................................................................................................................... 260
RETARDER OIL TEMPERATURE SENSOR....................................................................................................................................................................................................................................... 260
TORQUE CONVERTER OIL TEMPERATURE SENSOR............................................................................................................................................................................................................................... 260
AIR PRESSURE SENSOR................................................................................................................................................................................................................................................... 260
FUEL LEVEL SENSOR..................................................................................................................................................................................................................................................... 261
TRANSMISSION OIL FILTER SENSOR........................................................................................................................................................................................................................................ 262
RADIATOR WATER LEVEL SENSOR........................................................................................................................................................................................................................................... 262
STEERING OIL TEMPERATURE SENSOR....................................................................................................................................................................................................................................... 263
BRAKE STROKE SENSOR................................................................................................................................................................................................................................................... 263
PMC SYSTEM (MACHINE EQUIPPED WITH ELECTRONIC GOVERNOR) (OP)................................................................................................................................................................................................................... 264
SYSTEM DIAGRAM............................................................................................................................................................................................................................................................ 264
ELECTRIC CIRCUIT DIAGRAM.................................................................................................................................................................................................................................................. 266
POWER TRAIN MANAGEMENT CONTROLLER (PMC)................................................................................................................................................................................................................................... 267
MESSAGE DISPLAY (MOM)..................................................................................................................................................................................................................................................... 269
SENSOR, SWITCHES.......................................................................................................................................................................................................................................................... 271
ENGINE SPEED SENSOR................................................................................................................................................................................................................................................... 271
TRANSMISSION SPEED SENSOR............................................................................................................................................................................................................................................. 271
ACCELERATOR SENSOR.................................................................................................................................................................................................................................................... 272
SUSPENSION PRESSURE SENSOR............................................................................................................................................................................................................................................ 273
SENSORS, SWITCHES..................................................................................................................................................................................................................................................... 274
ENGINE OIL LEVEL SENSOR............................................................................................................................................................................................................................................... 274
BRAKE OIL LEVEL SENSOR................................................................................................................................................................................................................................................ 274
HYDRAULIC OIL LEVEL SENSOR............................................................................................................................................................................................................................................ 275
RETARDER OIL LEVEL SENSOR............................................................................................................................................................................................................................................. 275
AIR CLEANER CLOGGING SENSOR........................................................................................................................................................................................................................................... 275
RETARDER BRAKE WEAR SENSOR............................................................................................................................................................................................................................................ 276
HYDRAULIC FILTER SENSOR............................................................................................................................................................................................................................................... 276
RETARDER OIL FILTER SENSOR............................................................................................................................................................................................................................................ 276
FULL-FLOW FILTER SENSOR............................................................................................................................................................................................................................................... 277
BATTERY ELECTROLYTE LEVEL SENSOR...................................................................................................................................................................................................................................... 277
MAINTENANCE MONITOR SYSTEM.................................................................................................................................................................................................................................................... 278
SYSTEM DIAGRAM............................................................................................................................................................................................................................................................ 278
MONITOR PANEL............................................................................................................................................................................................................................................................. 279
MONITOR DISPLAY, FUNCTIONS................................................................................................................................................................................................................................................ 280
FUNCTIONS OF SWITCHES..................................................................................................................................................................................................................................................... 282
SENSORS, SWITCHES......................................................................................................................................................................................................................................................... 284
ENGINE OIL LEVEL SENSOR............................................................................................................................................................................................................................................... 284
RADIATOR WATER LEVEL SENSOR........................................................................................................................................................................................................................................... 284
TRANSMISSION OIL LEVEL SENSOR......................................................................................................................................................................................................................................... 284
HYDRAULIC OIL LEVEL SENSOR............................................................................................................................................................................................................................................ 285
RETARDER OIL LEVEL SENSOR............................................................................................................................................................................................................................................. 285
AIR FILTER CLOGGING SENSOR............................................................................................................................................................................................................................................ 285
RETARDER BRAKE WEAR SENSOR............................................................................................................................................................................................................................................ 286
HYDRAULIC FILTER SENSOR............................................................................................................................................................................................................................................... 286
RETARDER OIL FILTER SENSOR............................................................................................................................................................................................................................................ 286
TRANSMISSION OIL FILTER SENSOR........................................................................................................................................................................................................................................ 286
BATTERY ELECTROLYTE LEVEL SENSOR...................................................................................................................................................................................................................................... 287
TORQUE CONVERTER OIL TEMPERATURE SWITCH............................................................................................................................................................................................................................... 287
RETARDER OIL TEMPERATURE SWITCH....................................................................................................................................................................................................................................... 287
ABS/ASR SYSTEM................................................................................................................................................................................................................................................................ 288
SYSTEM CIRCUIT DIAGRAM.................................................................................................................................................................................................................................................... 288
PRINCIPLE OF OPERATION.................................................................................................................................................................................................................................................... 290
WHEN ABS IS ACTUATED...................................................................................................................................................................................................................................................... 291
WHEN ASR IS ACTUATED...................................................................................................................................................................................................................................................... 292
SYSTEM STRUCTURE DIAGRAM.................................................................................................................................................................................................................................................. 293
ABS/ASR ELECTRICAL CIRCUIT DIAGRAM........................................................................................................................................................................................................................................ 295
ABS/ASR CONTROLLER (ECU)...................................................................................................................................................................................................................................................... 297
ABS PRESSURE CONTROL VALVE.................................................................................................................................................................................................................................................... 298
ASR CONTROL VALVE............................................................................................................................................................................................................................................................. 301
WHEEL SPEED SENSOR............................................................................................................................................................................................................................................................ 303
RELAY......................................................................................................................................................................................................................................................................... 303
ASR-โ
ก SYSTEM (IF EUQIPPED).................................................................................................................................................................................................................................................... 304
SYSTEM DIAGRAM............................................................................................................................................................................................................................................................ 304
BASIC OPERATION........................................................................................................................................................................................................................................................... 305
SYSTEM CONFIGURATION...................................................................................................................................................................................................................................................... 305
CONTROLLER OF AUTOMATIC SPIN REGULATOR.................................................................................................................................................................................................................................... 308
HYDRAULIC TANK PRESSURIZING SYSTEM (HIGH ALTITUDE SPECIFICATION).............................................................................................................................................................................................................. 309
ELECTRICAL CIRCUIT DIAGRAM OF HYDRAULIC TANK PRESSURIZING SYSTEM.......................................................................................................................................................................................................... 311
20 TESTING AND ADJUSTING.......................................................................................................................................................................................................................................................... 312
STANDARD VALUE TABLE FOR ENGINE BELATED PARTS................................................................................................................................................................................................................................. 313
STANDARD VALUE TABLE FOR CHASSIS.............................................................................................................................................................................................................................................. 314
STANDARD VALUE TABLE FOR ELECTRICAL PARTS..................................................................................................................................................................................................................................... 320
TESTING AND ADJUSTING......................................................................................................................................................................................................................................................... 334
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING.......................................................................................................................................................................................................................... 335
ADJUSTING VALVE CLEARANCE................................................................................................................................................................................................................................................. 337
MEASURING COMPRESSION PRESSURE............................................................................................................................................................................................................................................ 338
MEASURING BLOWBY PRESSURE................................................................................................................................................................................................................................................. 339
MEASURING BOOST PRESSURE.................................................................................................................................................................................................................................................. 340
MEASURING EXHAUST TRMPERATURE............................................................................................................................................................................................................................................. 341
TESTING AND ADJUSTING FUEL INJECTION TIMING............................................................................................................................................................................................................................... 342
ADJUSTING ALTERNATOR BELT TENSION......................................................................................................................................................................................................................................... 345
ADJUSTING ENGINE SPEED SENSOR............................................................................................................................................................................................................................................. 346
ADJSUTING TRANSMISSION SPEED SENSOR....................................................................................................................................................................................................................................... 346
ADJUSTING ACCELERATOR PEDAL............................................................................................................................................................................................................................................... 347
TESTING HYDRAULIC PRESSURE OF TORQUE CONVERTER VALVE...................................................................................................................................................................................................................... 348
TESTING ECMV HYDRAULIC PRESSURE........................................................................................................................................................................................................................................... 349
TESTING TRANSMISSION LUBRICATION PRESSURE................................................................................................................................................................................................................................. 352
TESTING TORQUE CONVERTER STALL SPEED...................................................................................................................................................................................................................................... 353
TESTING BRAKE PRESSURE.................................................................................................................................................................................................................................................... 355
BLEEDING AIR FROM BRAKE CIRCUIT........................................................................................................................................................................................................................................... 356
TESTING WEAR OF FRONT BRAKE PAD........................................................................................................................................................................................................................................... 356
TESTING WEAR OF REAR BRAKE DISC........................................................................................................................................................................................................................................... 357
ADJUSTING PARKING BRAKE................................................................................................................................................................................................................................................... 359
TESTING BRAKE PERFORMANCE................................................................................................................................................................................................................................................. 360
TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER (WITH VARIABLE DAMPING FORCE SELECTOR VALVE).............................................................................................................................................................................. 361
TESTING AND ADJUSTING INVERTED TYPE REAR SUSPENSION CYLINDER.............................................................................................................................................................................................................. 365
TESTING AND ADJUSTING SUSPENSION AIR CYLINDER............................................................................................................................................................................................................................. 369
TESTING AND ADJUSTING AIR PRESSURE IN AIR CIRCUIT......................................................................................................................................................................................................................... 370
INSPECTION OF AIR DRIER (DESICCANT TYPE).................................................................................................................................................................................................................................. 371
ADJUSTING HOIST LEVER LINKAGE............................................................................................................................................................................................................................................. 373
ADJUSTING BODY POSITIONER................................................................................................................................................................................................................................................. 374
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING, HOIST CIRCUIT....................................................................................................................................................................................................... 375
AIR BLEEDING FROM STEERING CYLINDER....................................................................................................................................................................................................................................... 377
ADJUSTING ELECTRONIC MONITOR (SPEEDOMETER,TACHOMETER MODULE).............................................................................................................................................................................................................. 378
ADJUSTING Q [FUEL INJECTION AMOUNT] WHEN REPLACING ENGINE CONTROLLER...................................................................................................................................................................................................... 379
SETTING ROTARY SWITCH (MODEL DATA, NETWORK DATA) WHEN REPLACING TRANSMISSION CONTROLLER................................................................................................................................................................................... 380
METHOD OF DELETING DATA FROM ENGINE CONTROLER,TRANSMISSION CONTROLLER AND PMC MEMORY (CONTROL FROM MONITOR PANEL)......................................................................................................................................................... 381
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM.................................................................................................................................................................................................... 384
PROCEDURE FOR OPERATING MODULATION CHECKER................................................................................................................................................................................................................................ 390
ADJUSTING HYDRAULIC TANK PRESSURE (HIGH ALTITUDE SPECIFICATION)........................................................................................................................................................................................................... 395
PERFORMING PM CLINIC USING MANUAL SNAPSHOT (=QUICK PM).................................................................................................................................................................................................................... 396
PM-CLINIC SERVICE......................................................................................................................................................................................................................................................... 400
TROUBLESHOOTING............................................................................................................................................................................................................................................................... 402
POINTS TO REMEMBER WHEN TROUBLESHOOTING................................................................................................................................................................................................................................... 403
SEQUENCE OF EVENTS IN TROUBLESHOOTING..................................................................................................................................................................................................................................... 404
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.......................................................................................................................................................................................................................... 405
CHECKS BEFORE TROUBLESHOOTING............................................................................................................................................................................................................................................. 413
TYPE OF CONNECTOR AND POSITION OF INSTALLATION............................................................................................................................................................................................................................ 415
CONNECTOR PIN ALLOCATION CHART............................................................................................................................................................................................................................................ 421
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS................................................................................................................................................................................................................................ 426
EXPLANATIONS OF FUNCTIONS (CONTROL MECHANISM) OF ELECTRICAL SYSTEM........................................................................................................................................................................................................ 451
MONITOR PANEL USER CODES AND SERVICE MODE FUNCTION........................................................................................................................................................................................................................ 458
SELF-DIAGNOSTIC DISPLAY METHOD FOR MONITOR PANEL AND CONTROLLERS.......................................................................................................................................................................................................... 474
TABLE OF SERVICE CODES AND USER CODES..................................................................................................................................................................................................................................... 481
METHOD OF USING JUDGEMENT TABLE........................................................................................................................................................................................................................................... 491
METHOD OF USING TROUBLESHOOTING CHARTS.................................................................................................................................................................................................................................... 492
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (ELECTRONIC GOVERNOR SPECIFICATION G MODE).................................................................................................................................................................................... 494
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE........................................................................................................................................................................................................ 495
JUDGMENT TABLE FOR TRANSMISSION CONTROLLER, TRANSMISSION RELATED PARTS................................................................................................................................................................................................ 503
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE CONTROLLER SYSTEM............................................................................................................................................................................................................... 507
G-1 C010 [E.<-->1.0] ABNORMALITY IN POWER SOURCE...................................................................................................................................................................................................................... 508
G-2 C011 [E.<-->1.1] ABNORMALITY IN CONTROLLER........................................................................................................................................................................................................................ 508
G-3 C012 [E.<-->1.2] ABNORMALITY IN RACK SENSOR SYSTEM................................................................................................................................................................................................................ 509
G-4 C013 [E.<-->1.3] ABNORMALITY IN RACK SENSOR SYSTEM LEFT BANK...................................................................................................................................................................................................... 510
G-5 C014 [E.<-->1.4] ABNORMALITY IN GOVERNOR SOLENOID SYSTEM RIGHT BANK............................................................................................................................................................................................... 511
G-6 C015 [E.<-->1.5] ABNORMALITY IN GOVERNOR SOLENOID SYSTEM LEFT BANK................................................................................................................................................................................................ 512
G-7 C016 [E.<-->1.6] ABNORMALITY IN GOVERNOR CUT RELAY SYSTEM RIGHT BANK.............................................................................................................................................................................................. 513
G-8 C017 [E.<-->1.7] ABNORMALITY IN GOVERNOR CUT RELAY SYSTEM LEFT BANK............................................................................................................................................................................................... 514
G-9 C018 [E.<-->1.8] ABNORMALITY IN RACK SENSOR POWER SOURCE SYSTEM................................................................................................................................................................................................... 515
G-10 C019 [E.<-->1.9] ABNORMALITY IN GOVERNOR SERVO SYSTEM RIGHT BANK................................................................................................................................................................................................. 516
G-11 C01A [E.<-->1.A] ABNORMALITY IN GOVERNOR SERVO SYSTEM LEFT BANK.................................................................................................................................................................................................. 516
G-12 C01b [E.<-->1.b] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM A..................................................................................................................................................................................................... 517
G-13 C01C [E.<-->1.C] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM B..................................................................................................................................................................................................... 518
G-14 C01d [E.<-->1.d] ABNORMALITY IN PRE-STROKE SOLENOID SYSTEM RIGHT BANK............................................................................................................................................................................................ 519
G-15 C01E [E.<-->1.E] ABNORMALITY IN PRE-STROKE SOLENOID SYSTEM LEFT BANK............................................................................................................................................................................................. 520
G-16 C021 [E.<-->2.1] MISTAKEN CONNECTION OF CONNECTOR................................................................................................................................................................................................................ 521
G-17 C022 [E.<-->2.2] ENGINE OVERRUN.................................................................................................................................................................................................................................. 522
G-18 C023 [E.<-->2.3] ENGINE OVERHEATING.............................................................................................................................................................................................................................. 522
G-19 C024 [E.<-->2.4] DROP IN ENGING OIL PRESSURE..................................................................................................................................................................................................................... 522
G-20 C031 [E.<-->3.1] ABNORMALITY IN ACCELERATION SENSOR SYSTEM....................................................................................................................................................................................................... 523
G-21 C034 [E.<-->3.4] ABNORMALITY IN ENGINE COOLANT TEMPERATURE SYSTEM................................................................................................................................................................................................ 526
G-22 C036 [E.<-->3.6] ABNORMALITY IN ENGINE OIL PRESSURE SENSOR....................................................................................................................................................................................................... 527
G-23 C055 [E.<-->5.5] ABNORMALITY IN NETWORK.......................................................................................................................................................................................................................... 528
G-24 C056 [E.<-->5.6] ABNORMALITY IN SOLENOID POWER SOURCE SYSTEM RIGHT............................................................................................................................................................................................... 529
G-25 C057 [E.<-->5.7] ABNORMALITY IN SOLENOID POWER SOURCE SYSTEM LEFT................................................................................................................................................................................................ 529
G-26 C058 [E.<-->5.8] ABNORMALITY IN BACKUP POWER SOURCE SYSTEM....................................................................................................................................................................................................... 529
G-27 C059 [E.<-->5.9] ABNORMALITY IN BACKUP POWER SOURCE SYSTEM....................................................................................................................................................................................................... 531
G-28 C0C2 [E.<-->C.2] DEFECTIVE MODEL SELECTION DATA.................................................................................................................................................................................................................. 532
G-29 C0C4 [E.<-->C.4] ABNORMALITY IN ACCELERATION SENSOR SYSTEM....................................................................................................................................................................................................... 533
G-30 C0C5 [E.<-->C.5] ABNORMALITY IN IDLE VALIDATION.................................................................................................................................................................................................................. 536
G-31 ENGINE DOES NOT START............................................................................................................................................................................................................................................ 541
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)................................................................................................................................................................................................................................. 544
METHOD OF USING TROUBLESHOOTING CHART................................................................................................................................................................................................................................. 545
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)......................................................................................................................................................................................................... 549
S-2 ENGINE DOES NOT START............................................................................................................................................................................................................................................. 551
a) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)....................................................................................................................................................................................... 551
b) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)..................................................................................................................................................................................... 552
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR).............................................................................................................................................................................................................. 553
S-4 ENGINE STOPS DURING OPERATIONS.................................................................................................................................................................................................................................... 554
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)......................................................................................................................................................................................................................... 556
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER).............................................................................................................................................................................................................................. 557
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION).................................................................................................................................................................................................................... 558
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)........................................................................................................................................................................................................... 559
S-9 OIL BECOMES CONTAMINATED QUICKLY.................................................................................................................................................................................................................................. 560
S-10 FUEL CONSUMPTION IS EXCESSIVE.................................................................................................................................................................................................................................... 561
S-11 OIL IS IN COOLING, OR WATER SPURTS BACK, OR COOLANT LEVEL GOES DOWN.............................................................................................................................................................................................. 562
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)....................................................................................................................................................................................................... 563
S-13 OIL LEVEL RISES.................................................................................................................................................................................................................................................. 564
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)............................................................................................................................................................................................................... 565
S-15 ABNORMAL NOISE IS MADE........................................................................................................................................................................................................................................... 566
S-16 VIBRATION IS EXCESSIVE........................................................................................................................................................................................................................................... 568
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A MODE)................................................................................................................................................................................................................ 569
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM................................................................................................................................................................................ 573
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE........................................................................................................................................................................................................ 575
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER, TRANSMISSION RELATED PARTS............................................................................................................................................................................................... 595
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM......................................................................................................................................................................................................... 597
A-1 ABNORMALITY IN POWER SOURCE SYSTEM................................................................................................................................................................................................................................ 599
a) [u.u][OFF]CONTROLLER SELF-DIAGNOSTIC DISPLAY LED DOES NOT LIGHT UP............................................................................................................................................................................................. 599
b) bOO1 [E. <-->0.1, E.C<-->0.1] DROP IN VOLTAGE OF CONTROLLER POWER SOURCE IS DISPLAYED.......................................................................................................................................................................... 600
c) bOdA [E. <-->d.A, E.C<-->d.A] DROP IN VOLTAGE OF BATTERY DIRECT POWER SOURCE IS DISPLAYED...................................................................................................................................................................... 601
d) bOdb [E. <-->d.b, E.C<-->d.b] DROP IN VOLTAGE OF MAIL POWER SOURCE IS DISPLAYED................................................................................................................................................................................ 602
e) bOO2 [E. <-->0.2, E.C<-->0.2] ABNORMALITAY IN TRANSMISSION CUT RELAY POWER SOURCE IS DISPLAYED................................................................................................................................................................. 603
A-2 bOO3 [E. <-->0.3, E.C<-->0.3] ABNORMALITY IN NEUTRAL SAFETY SYSTEM IS DISPLAYED................................................................................................................................................................................... 604
A-3 bOO5 [E. <-->0.5, E.C<-->0.5] DOUBLE ENGAGEMENT FOR CLUTCH IS DISPLAYED........................................................................................................................................................................................... 605
A-4 bOO6 [E. <-->0.6, E.C<-->0.6] ABNORMALITY IN TRANSMISSION [CUT RELAY] SYSTEM DISPLAYED............................................................................................................................................................................ 606
A-5 bOO8 [E. <-->0.8, E.C<-->0.8] ABNORMALITY IN REAR BRAKE SOLENOID SYSTEM IS DISPLAYED.............................................................................................................................................................................. 607
A-6 bOO9 [E. <-->0.9, E.C<-->0.9] ABNORMALITY IN EXHAUST BRAKE SOLENOID SYSTEM IS DISPLAYED........................................................................................................................................................................... 608
A-7................................................................................................................................................................................................................................................................... 609
a) bOC4 [E. <-->C.4, E.C<-->C.4] SHORT CIRCUIT WITH GROUND IN BCV REAR SOLENOID IS DISPLAYED...................................................................................................................................................................... 609
b) bOC6 [E. <-->C.6, E.C<-->C.6] SHORT CIRCUIT IN BCV REAR SOLENOID IS DISPLAYED.................................................................................................................................................................................. 610
c) bOC8 [E. <-->C.8, E.C<-->C.8] DISCONNECTION IN BCV REAR SOLENOID IS DISPLAYED.................................................................................................................................................................................. 611
A-8 ABNORMALITY IN SPEED SENSOR SYSTEM................................................................................................................................................................................................................................ 612
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).... 612
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............................................................................... 614
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................................................................. 615
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............................................ 616
A-9 SPEED SENSOR SYSTEM, CLUTCH SLIPPING.............................................................................................................................................................................................................................. 617
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..................................................................................................................................... 617
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..................................................................................................................... 618
A-10 ABNORMALITY IN MODEL SELECTION (WIRING HARNESS) IS DISPLAYED..................................................................................................................................................................................................... 619
a) b014 [E. <-->1.4, E.C<-->1.4] ABNORMALITY IN MODEL SELECTION (WIRING HARNESS) IS DISPLAYED..................................................................................................................................................................... 619
b) b0A1 [E. <-->A.1, E.C<-->A.1] ABNORMALITY IN MODEL SELECTION (ROTARY SWITCH) IS DISPLAYED...................................................................................................................................................................... 620
A-11 ABNORMALITY IN SHIFT LEVER SYSTEM................................................................................................................................................................................................................................ 621
a) b007 [E. <-->0.7, E.C<-->0.7] SHORT CIRCUIT IN SHIFT LEVER ASSEMBLY POWER SOURCE IS DISPLAYED.................................................................................................................................................................. 621
b) b015 [E. <-->1.5, E.C<-->1.5] SHIFT LEVER POSITION SIGNAL INPUT FOR 2 OR MORE SYSTEM IS DISPLAYED.............................................................................................................................................................. 622
c) b016 [E. <-->1.6, E.C<-->1.6] SHIFT LEVER POSITION SIGNAL IS NOT INPUT......................................................................................................................................................................................... 624
A-12 b017 [E. <-->1.7, E.C<-->1.7] ABNORMALITY IN ACCELERATOR SIGNAL IS DISPLAYED..................................................................................................................................................................................... 626
A-13 b019 [E. <-->1.9, E.C<-->1.9] ABNORMALITY IN TRANSMISSION OIL TRMPERATURE SENSOR IS DISPLAYED.................................................................................................................................................................... 627
A-14 ABNORMALITY IN PRESSURE CONTROL VALVE SYSTEM..................................................................................................................................................................................................................... 628
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........................................................................................................................................ 628
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........................................................................................................................................ 630
b-1) INSPECTING FILL SIGNAL SYSTEM............................................................................................................................................................................................................................ 630
b-2) b042 [E. <-->4.2, E.C<-->4.2] ใป b043 [E. <-->4.3, E.C<-->4.3] INSPECTING TRANSMISSION INPUT SHAFT SPEED SIGNAL SYSTEM,H,L CLUTCH SYSTEM (CHECK CLUTCH SLIP).............................................................................................. 631
b-3) b044 [E. <-->4.4, E.C<-->4.4] ใป b048 [E. <-->4.8, E.C<-->4.8] INSPECTING TRANSMISSION OUTPUT SHAFT SPEED SIGNAL SYSTEM, 1-4, R CLUTCH SYSTEM (INSPECTING CLUTCH SLIP).................................................................................... 631
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)......................................................................................................................................... 632
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............................................................................................................................... 633
A-17 ABNORMALITY IN SENSOR SYSTEM..................................................................................................................................................................................................................................... 635
a) b0A2 [E. <-->A.2, E.C<-->A.2] ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE SENSOR SYSTEM IS DISPLAYED....................................................................................................................................................... 635
b) b0A3 [E. <-->A.3, E.C<-->A.3] ABNORMALITY IN FUEL LEVEL SENSOR SYSTEM IS DISPLAYED............................................................................................................................................................................. 636
c) b0b2 [E. <-->b.2, E.C<-->b.2] ABNORMALITY IN COOLANT TEMPERATURE SENSOR SYSTEM IS DISPLAYED.................................................................................................................................................................... 637
d) b0b3 [E. <-->b.3, E.C<-->b.3] ABNORMALITY IN AIR PRESSURE SENSOR SYSTEM IS DISPLAYED........................................................................................................................................................................... 638
e) b0b4 [E. <-->b.4, E.C<-->b.4] ABNORMALITY IN RETARDER BRAKE OIL TEMPERATURE SENSOR IS DISPLAYED................................................................................................................................................................ 639
A-18 WARNING DISPLAY.................................................................................................................................................................................................................................................. 640
a) b0d1 [E. <-->d.1, E.C<-->d.1] TRANSMISSION FILTER CLOGGED WARNING IS DISPLAYED................................................................................................................................................................................. 640
b) b0d5 [E. <-->d.5, E.C<-->d.5] TILT WARNING IS DISPLAYED........................................................................................................................................................................................................ 641
c) b0d6 [E. <-->d.6, E.C<-->d.6] DROP IN RADIATOR WATER LEVEL WARNING IS DISPLAYED................................................................................................................................................................................ 642
d) b0d7 [E. <-->d.7, E.C<-->d.7] BATTERY CHARGE LEVEL WARNING IS DISPLAYED........................................................................................................................................................................................ 643
e) b0E5 [E. <-->E.5, E.C<-->E.5] STEERING OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED........................................................................................................................................................................... 644
f) b0F5 [E. <-->F.5, E.C<-->F.5] DROP IN ENGINE OIL PRESSURE WARNING IS DISPLAYED (MECHANICAL GOVERNOR SPECIFICATION MACHINE)..................................................................................................................................... 645
g) b0F6 [E. <-->F.6, E.C<-->F.6] REAR BRAKE OIL PRESSURE WARNING IS DISPLAYED..................................................................................................................................................................................... 646
A-19 b0b7 [E. <-->b.7, E.C<-->b.7] ABNORMALITY IN ENGINE OIL PRESSURE SYSTEM SENSOR IS DISPLAYED (MECHANICAL GOVERNOR SPECIFITION MACHINE)............................................................................................................................ 647
A-20 b0C1 [E. <-->C.1, E.C<-->C.1] ABNORMALITY IN CONNECTOR CONNECTION IS DISPLAYED................................................................................................................................................................................... 648
A-21 ................................................................................................................................................................................................................................................................. 649
a) b0d2 [E. <-->d.2, E.C<-->d.2] TORQUE CONVERTER OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED................................................................................................................................................................... 649
b) b0d3 [E. <-->d.3, E.C<-->d.3] ENGINE COOLANT TEMPERATURE OVERHEAT WARNING IS DISPLAYED......................................................................................................................................................................... 649
c) b0E9 [E. <-->E.9, E.C<-->E.9] AIR PRESSURE DROP WARNING IS DISPLAYED........................................................................................................................................................................................... 649
d) b0F3 [E. <-->F.3, E.C<-->F.3] RETARDER BRAKE OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED..................................................................................................................................................................... 649
e) b0d8 [E. <-->d.8, E.C<-->d.8] ENGINE OVERRUN ACTUATED IS DISPLAYED............................................................................................................................................................................................. 650
f) b0d9 [E. <-->d.9, E.C<-->d.9] ENGINE OVERSHOOT ACTUATED IS DISPLAYED........................................................................................................................................................................................... 650
TROUBLESHOOTING OF SUSPENSION CONTROLLER SYSTEM (SP MODE)................................................................................................................................................................................................................. 651
JUDGMENT TABLE FOR SUSPENSION CONTROLLER, SUSPENSION RELATED PARTS.................................................................................................................................................................................................... 652
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE........................................................................................................................................................................................................ 654
ELECTRICAL CIRCUIT DIAGRAM OF SUSPENSION CONTROLLER SYSTEM............................................................................................................................................................................................................ 658
SP-1 d001 [ALL OFF or E.<-->01] ABNORMALITY IN POWER SOURCE IS DISPLAYED.............................................................................................................................................................................................. 660
SP-2 d011 [E.<-->11 IS DISPLAYED] ABNORMALITY IN PRESSURE SENSOR [RIGHT] SYSTEM IS DISPLAYED.......................................................................................................................................................................... 661
SP-3 d012 [E.<-->12 IS DISPLAYED] ABNORMALITY IN PRESSURE SENSOR [LEFT] SYSTEM IS DISPLAYED........................................................................................................................................................................... 662
SP-4 d015 [E.<-->15 IS DISPLAYED] ABNORMALITY IN TRAVEL SPEED SENSOR SYSTEM IS DISPLAYED.............................................................................................................................................................................. 663
SP-5 d016 [E.<-->16 IS DISPLAYED] ABNORMALITY IN STEERING SENSOR SYSTEM IS DISPLAYED.................................................................................................................................................................................. 664
SP-6 d0C2 [E.<-->C2 IS DISPLAYED] DEFECTIVE MODEL SELECTION DATA IS DISPLAYED......................................................................................................................................................................................... 665
SP-7 d021 [E.<-->21 IS DISPLAYED] ABNORMALITY IN SOLENOID [1] SYSTEM IS DISPLAYED..................................................................................................................................................................................... 666
SP-8 d022 [E.<-->22 IS DISPLAYED] ABNORMALITY IN SOLENOID [2] SYSTEM IS DISPLAYED..................................................................................................................................................................................... 667
SP-9 d023 [E.<-->23 IS DISPLAYED] ABNORMALITY IN SOLENOID [3] SYSTEM IS DISPLAYED..................................................................................................................................................................................... 668
SP-10 d0C1 [E.<-->C1 IS DISPLAYED] DISCONNECTION IN NETWROK IS DISPLAYED.............................................................................................................................................................................................. 669
SP-11 d0C3 [E.<-->C3 IS DISPLAYED] DEFECTIVE TRAVEL SPEED COMPENSATION DATA IS DISPLAYED.............................................................................................................................................................................. 670
TROUBLESHOOTING OF PAYLOAD METER (PRINTER TYPE) SYSTEM (LP MODE).......................................................................................................................................................................................................... 671
SERVICE CODES AND SELF-DIAGNOSIS OF PAYLOAD METER (PRINTER TYPE)...................................................................................................................................................................................................... 672
ELECTRIC CIRCUIT DIAGRAM FOR PAYLOAD METER (PRINTER TYPE) SYSTEM...................................................................................................................................................................................................... 673
LP-1 NO DISPLAY APPEARS WHEN STARTING SWITCH IS TURNED ON............................................................................................................................................................................................................. 675
LP-2 CALIBRATION DEMAND (CAL FLASHES) IS SHOWN CONTINUOUSLY AFTER STARTING SWITCH IS TURNED ON ....................................................................................................................................................................... 676
LP-3 CALIBRATION CANNOT BE CARRIED OUT ............................................................................................................................................................................................................................... 678
LP-4 AFTER STARTING SWITCH IS TURNED ON,ALL EXTERNAL DISPLAY LAMPS DO NOT LIGHT UP.................................................................................................................................................................................... 681
LP-5 CONDITION DOES NOT EXIST FOR LAMPS TO LIGHT UP,BUT EXERNAL DISPLAY LAMPS LIGHT UP................................................................................................................................................................................ 683
LP-6 LEVEL OF LIGHTING UP OF EXTERNAL DISPLAY LAMPS IS NOT CORRECT.................................................................................................................................................................................................... 684
LP-7 ABNORMALITY IN DISPLAY LOGIC..................................................................................................................................................................................................................................... 686
LP-8 E01-E04 IS DISPLAYED............................................................................................................................................................................................................................................. 691
LP-9 E11-E14 IS DISPLAYED............................................................................................................................................................................................................................................. 692
LP-10 E21-E28 IS DISPLAYED BY SENSOR CHECK............................................................................................................................................................................................................................ 693
LP-11 E31 IS DISPLAYED................................................................................................................................................................................................................................................ 694
LP-12 E32 IS DISPLAYED................................................................................................................................................................................................................................................ 696
LP-13 E41 IS DISPLAYED................................................................................................................................................................................................................................................ 698
LP-14 E42 IS DISPLAYED................................................................................................................................................................................................................................................ 699
LP-15 PRINTER DOES NOT PRINT ANYTHING (BLANK PAPER COMES OUT)......................................................................................................................................................................................................... 700
LP-16 PRINTER PRINTS ONLY "NO DATA"................................................................................................................................................................................................................................... 700
LP-17 PRINTER DOES NOT PRINT OUT WHEN PRT SWITCH IS PRESSED........................................................................................................................................................................................................... 700
LP-18 "PAPE" FLASHES.................................................................................................................................................................................................................................................. 701
LP-19 TIME IS WRONG................................................................................................................................................................................................................................................... 701
LP-20 E33 IS DISPLAYED................................................................................................................................................................................................................................................ 701
TROUBLESHOOTING OF PAYLOAD METER โ
ก (CARD TYPE) SYSTEM (LC MODE)........................................................................................................................................................................................................... 702
SERVICE CODES AND SELF-DIAGNOSIS OF PAYLOAD METER โ
ก (CARD TYPE)....................................................................................................................................................................................................... 703
ELECTRICAL CIRCUIT DIAGRAM FOR PAYLOAD METER โ
ก (CARD TYPE) SYSTEM..................................................................................................................................................................................................... 706
LC-1 NO DISPLAY APPEARS WHEN STARTING SWITCH IS TURNED ON ............................................................................................................................................................................................................ 708
LC-2 AFTER STARTING SWITCH IS TURNED ON,ALL EXTERNAL DISPLAY LAMPS DO NOT LIGHT UP.................................................................................................................................................................................... 709
LC-3 CONDITION DOES NOT EXIST FOR LAMPS TO LIGHT UP,BUT EXTERNAL DISPLAY LAMPS LIGHT UP............................................................................................................................................................................... 710
LC-4 LEVEL OF LIGHTING UP OF EXTERNAL DISPLAY LAMPS IS NOT CORRECT.................................................................................................................................................................................................... 711
LC-5 CYCLE DATA IS NOT RECOREDE,ON/OFF DATA IS NOT RECORDED:BATTERY CHARGE SIGNAL SYSTEM:ENGINE IS NOT STARTED IS DETECTED............................................................................................................................................ 713
LC-6 CALIBRATION CANNOT BE CARRIED OUT,TIME DISPLAY DOES NOT MATCH CONDITIONS:SHIFT LEVER N POSITION SIGNAL SYSTEM.................................................................................................................................................... 714
LC-7 ABNORMALITY IN DISPLAY LOGIC..................................................................................................................................................................................................................................... 715
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................................................................................................................................. 717
LC-9 F-09 IS DISPLAYED:DROP IN VOLTAGE OF BACK-UP BATTERY BUILT INTO PAYLOAD METER.................................................................................................................................................................................... 718
LC-10 FULL DISPLAY APPEARS............................................................................................................................................................................................................................................ 718
LC-11 F-20 IS DISPLAYED:SENSOR POWER SOURCE VOLTAGE SYSTEM............................................................................................................................................................................................................ 719
LC-12 F-21 - F-24 IS DISPLAYED:DISCONNECTION,SHORT CIRCUIT WITH GROUND SUSPENSION PRESSURE SENSOR SYSTEM.............................................................................................................................................................. 720
LC-13 F-25 - F-28 IS DISPLAYED:SHORT CIRCUIT IN SUSPENSION PRESSURE SENSOR SYSTEM POWER SOURCE........................................................................................................................................................................ 722
LC-14 F.CAL IS DISPLAYED:CALIBRATION NOT CARRIED OUT,DAMAGED DATA INSIDE PAYLOAD METER................................................................................................................................................................................ 723
LC-15 F-41 - F-45 IS DISPLAYED:SHORT CIRCUIT IN EXTERNAL DISPLAY LAMP SYSTEM POWER SOURCE............................................................................................................................................................................. 724
LC-16 L-BAD IS DISPLAYED:CYCLE DATA SAVED WHEN MACHINE WAS SWAYING.................................................................................................................................................................................................... 726
LC-17 MACHINE IS NOT LOADING BUT EXTERNAL DISPLAY LAMPS GIVE LOAD ESTIMATE DISPLAY. AFTER LOADING,DISPLAY SWITCHES TO TIME DISPLAY BEFORE TRAVELING 160m.............................................................................................................. 727
LC-18 F-31 IS DISPLAYED:DISCONNECTION,SHORT CIRCUIT WITH GROUND IN CLINOMETER SYSTEM.................................................................................................................................................................................. 728
LC-19 F-32 IS DISPLAYED:SHORT CIRCUIT WITH CLINOMETER SYSTEM POWER SOURCE............................................................................................................................................................................................. 729
LC-20 F-18 IS DISPLAYED:DISCONNECTION IN BATTERY CHARGE SIGNAL........................................................................................................................................................................................................ 730
LC-21 F-93 - 99 ARE DISPLAYED:ABNORMALITY IN NETWORK (WHEN PMC IS INSTALLED).......................................................................................................................................................................................... 731
LC-22 F-71,73,80,91,92 ARE DISPLAYED:(WHEN PMC,TALKS ARE INSTALLED)................................................................................................................................................................................................... 732
TROUBLESHOOTING OF ARSC [AUTOMATIC RETARDER SPEED CONTROLLER] SYSTEM (R MODE)............................................................................................................................................................................................. 733
OUTLINE............................................................................................................................................................................................................................................................... 734
ELECTRICAL CIRCUIT DIAGRAM FOR ARSC (AUTOMATIC RETARDER SPEED CONTROLLER) SYSTEM...................................................................................................................................................................................... 738
R-1 0.1 (ABNORMALITY IN POWER SOURCE VOLTAGE) IS DISPLAYED............................................................................................................................................................................................................ 740
R-2 1.0 (DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED.................................................................................................................................................................................................... 741
R-3 1.3 (DISCONNECTION IN TRANSMISSION OUTPUT SHAFT SPEED SENSOR SYSTEM) IS DISPLAYED................................................................................................................................................................................. 742
R-4 1.5 (FAILURE IN RETARDER OIL TEMPERATURE SENSOR SYSTEM) IS DISPLAYED.............................................................................................................................................................................................. 743
R-5 1.7 (FAILURE IN ACCELERATOR SIGNAL SYSTEM) IS DISPLAYED........................................................................................................................................................................................................... 744
R-6 1.8 (FAILURE IN SUSPENSION PRESSURE SENSOR "LEFT" SYSTEM) IS DISPLAYED............................................................................................................................................................................................ 745
R-7 1.9 (FAILURE IN SUSPENSION PRESSURE SENSOR "RIGHT" SYSTEM) IS DISPLAYED........................................................................................................................................................................................... 746
R-8 4.2 (DISCONNECTION IN EXHAUST BRAKE SELECTOR SIGNAL SYSTEM) IS DISPLAYED.......................................................................................................................................................................................... 747
R-9 4.3 (DISCONNECTION IN ARSC CAUTION LAMP SYSTEM) IS DISPLAYED...................................................................................................................................................................................................... 748
R-10 4.4 (DISCONNECTION IN READY LAMP SYSTEM) IS DISPLAYED............................................................................................................................................................................................................ 749
R-11 4.5 (DISCONNECTION IN PANEL CAUTION AND BUZZER SYSTEM) IS DISPLAYED.............................................................................................................................................................................................. 750
R-12 5.2 (SHORT CIRCUIT WITH GROUND EXHAUST BRAKE SELECTOR SIGNAL OUTPUT SYSTEM) IS DISPLAYED......................................................................................................................................................................... 751
R-13 5.3 (SHORT CIRCUIT WITH GROUND IN ARSC CAUTION LAMP SYSTEM) IS DISPLAYED......................................................................................................................................................................................... 752
R-14 5.4 (SHORT CIRCUIT WITH GROUND IN READY OUTPUT CIRCUIT SYSTEM) IS DISPLAYED...................................................................................................................................................................................... 753
R-15 5.5 (SHORT CIRCUIT WITH GROUND IN PANEL CAUTION LAMP AND BUZZER OUTPUT SYSTEM) IS DISPLAYED...................................................................................................................................................................... 754
R-16 6.0 (FAILURE IN ENGINE SPEED SYSTEM) IS DISPLAYED................................................................................................................................................................................................................ 755
R-17 7.0 (DISCONNECTION IN TRAVEL SPEED DISPLAY UP OUTPUT SYSTEM) IS DISPLAYED........................................................................................................................................................................................ 756
R-18 7.1 (DISCONNECTION IN TRAVEL SPEED DISPLAY DOWN OUTPUT SYSTEM) IS DISPLAYED...................................................................................................................................................................................... 757
R-19 7.2 (DISCONNECTION IN TRAVEL SPEED DISPLAY CLEAR OUTPUT SYSTEM) IS DISPLAYED..................................................................................................................................................................................... 758
R-20 7.3 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY UP OUTPUT SYSTEM) IS DISPLAYED............................................................................................................................................................................ 759
R-21 7.4 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY DOWN OUTPUT SYSTEM) IS DISPLAYED.......................................................................................................................................................................... 760
R-22 7.5 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY CLEAR OUTPUT SYSTEM) IS DISPLAYED......................................................................................................................................................................... 761
R-23 8.1 (SHORT CIRCUIT WITH GROUND IN PRESSURE CONTROL VALVE SYSTEM) IS DISPLAYED.................................................................................................................................................................................... 762
R-24 8.3 (DISCONNECTION IN PRESSURE CONTROL VALVE SYSTEM) IS DISPLAYED................................................................................................................................................................................................ 763
R-25 8.5 (FAILURE IN PRESSURE CONTROL VALVE (PRESSURE CONTROL VALVE REMAINS OPEN)) IS DISPLAYED....................................................................................................................................................................... 764
R-26 8.7 (FAILURE IN PRESSURE CONTROL VALVE (PRESSURE CONTROL VALVE DOES NOT OPEN)) IS DISPLAYED...................................................................................................................................................................... 765
R-27 8.9 (SHORT CIRCUIT WITH GROUND IN PRESSURE SWITCH VALVE SYSTEM) IS DISPLAYED..................................................................................................................................................................................... 766
R-28 9.0 (DISCONNECTION IN PRESSURE SWITCH VALVE SYSTEM) IS DISPLAYED................................................................................................................................................................................................. 767
R-29 9.1 (FAILURE IN PRESSURE SWITCH VALVE SYSTEM (REMAINS OPEN)) IS DISPLAYED........................................................................................................................................................................................ 768
R-30 9.2 (FAILURE IN PRESSURE SWITCH VALVE SYSTEM (DOES NOT OPEN)) IS DISPLAYED....................................................................................................................................................................................... 769
R-31 9.3 (DISCONNECTION IN SYSTEM SWITCH SYSTEM) IS DISPLAYED......................................................................................................................................................................................................... 770
R-32 9.4 (SHORT CIRCUIT WITH GROUND IN SYSTEM SWITCH SYSTEM) IS DISPLAYED............................................................................................................................................................................................. 771
R-33 9.5 (DISCONNECTION,SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED SETTING SWITCH SYSTEM) IS DISPLAYED................................................................................................................................................................. 772
R-101 SET SPEED CANNOT BE SET......................................................................................................................................................................................................................................... 773
R-102 FAILURE CODE IS ALWAYS CLEARED (CONTROLLER DISPLAY WINDOW ALWAYS SHOWS "--") OR FAILURE CODE CANNOT BE CLEARED.................................................................................................................................................. 776
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)................................................................................................................... 777
R-104 ABNORMALITY APPEARS IN OTHER CONTROLLER......................................................................................................................................................................................................................... 777
R-105 WHEN TRAVELING DOWNHILL,EVEN WHEN SET SPEED IS EXCEEDED,NO CONTROL IS CARRIED OUT............................................................................................................................................................................... 778
R-106 MONITOR LAMP (BUZZER) STAYS ON (OR OFF)......................................................................................................................................................................................................................... 779
R-107 READY LAMP DOES NOT LIGHT UP (OR STAYS LIGHTED UP).............................................................................................................................................................................................................. 780
R-108 EXHAUST BRAKE DOES NOT WORK PROPERLY............................................................................................................................................................................................................................ 782
R-109 THERE IS DIFFERENCE BETWEEN TRAVEL SPEED ROD VALUE AND ACTUAL MACHINE VALUE..................................................................................................................................................................................... 784
R-110 RETARDER LAMP DOES NOT LIGHT UP,OR STAYS LIGHTED UP............................................................................................................................................................................................................. 787
R-111 TRAVEL SPEED DISPLAY ALWAYS GIVES DISPLAY (OR DOES NOT GIVE ANY DISPLAY)........................................................................................................................................................................................ 788
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)............................................................................................................................................................................................................... 789
H-1 MACHINE DOES NOT START............................................................................................................................................................................................................................................ 790
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY ................................................................................................................................................................................................................................. 792
H-3 LOCK-UP CLUTCH CANNOT BE DISENGAGED............................................................................................................................................................................................................................... 792
H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING......................................................................................................................................................................................................................... 793
H-5 TRANSMISSION DOES NOT SHIFT UP.................................................................................................................................................................................................................................... 793
H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING....................................................................................................................................................................................................................... 794
H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR.............................................................................................................................................................................................................. 798
H-8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH.......................................................................................................................................................................................................................... 800
H-9 TORQUE CONVERTER OIL PRESSURE IS LOW.............................................................................................................................................................................................................................. 801
H-10 FRONT BRAKE IS INEFFECTIVE,OR EFFECTIVE ONLY ON ONE SIDE......................................................................................................................................................................................................... 802
H-11 REAR BRAKE IS INEFFECTIVE,OR EFFECTIVE ONLY ON ONE SIDE.......................................................................................................................................................................................................... 803
H-12 STEERING WHEEL IS HEAVY.......................................................................................................................................................................................................................................... 804
H-13 STEERING WHEEL DOES NOT WORK..................................................................................................................................................................................................................................... 805
H-14 STEERING WHEEL VIBRATES.......................................................................................................................................................................................................................................... 805
H-15 HOIST CYLINDER LACKS LIFTING FORCE (LIFTING SPEED)............................................................................................................................................................................................................... 806
H-16 HOIST CYLINDER DOES NOT WORK..................................................................................................................................................................................................................................... 807
H-17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY........................................................................................................................................................................................................................... 808
H-18 AIR PRESSURE DOES NOT RISE....................................................................................................................................................................................................................................... 809
TROUBLESHOOTING OF MONITOR PANEL SYSTEM (P MODE).......................................................................................................................................................................................................................... 810
METHOD OF SELF-DIAGNOSTIC DISPLAY FOR MONITOR PANEL AND CONTROLLERS................................................................................................................................................................................................... 812
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE (MONITOR PANEL SYSTEM)................................................................................................................................................................................. 813
ELECTRICAL CIRCUIT DIAGRAM FOR MONITOR PANEL SYSTEM................................................................................................................................................................................................................... 817
P-1 CHECK PATTERN FOR WIRING HARNESSES BETWEEN MODULES................................................................................................................................................................................................................ 819
P-2 NOTHING ON MONITOR PANEL WORKS.................................................................................................................................................................................................................................... 823
P-3 LH,RH MODULE AND FUEL GAUGE DO NOT WORK........................................................................................................................................................................................................................... 824
P-4 LH,RH MODULE AND FUEL GAUGE DO NOT WORK........................................................................................................................................................................................................................... 825
P-5 RH MODULE DOES NOT WORK........................................................................................................................................................................................................................................... 826
P-6 LH MODULE DOES NOT WORK........................................................................................................................................................................................................................................... 827
P-7 TRAVEL CALCULATOR DOES NOT WORK................................................................................................................................................................................................................................... 828
P-8 SERVICE METER DISPLAY DOES NOT WORK CORRECTLY..................................................................................................................................................................................................................... 829
P-9 CENTRAL WARNING LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS FAILURE CODE [A002].................................................................................................................................................................................. 830
P-10 CENTRAL WARNING LAMP STAYS LIGHTED UP............................................................................................................................................................................................................................ 831
P-11 ALARM BUZZER DOES NOT WORK,OR MONITOR PANEL DETECTS FAILURE CODE [A003].......................................................................................................................................................................................... 832
P-12 ALARM BUZZER CONTINUES TO SOUND.................................................................................................................................................................................................................................. 833
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]............................ 834
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]........................................................................................................... 835
P-15 GAUGE DISPLAYS ARE ABNORMAL (NOTHING IS DISPLAYED,OR DISPLAY DOES NOT CHANGE).................................................................................................................................................................................... 836
P-16 COOLANT LEVEL DROP CAUTION LAMPS DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]..................................................................................................................................................................... 837
P-17 COOLANT LEVEL DROP CAUTION LAMP STAYS LIGHTED UP................................................................................................................................................................................................................. 838
P-18 EMERGENCY STEERING PILOT LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SEVICE CODE [A001].......................................................................................................................................................................... 839
P-19 EMERGENCY STEERING PILOT LAMP STAYS LIGHTED UP................................................................................................................................................................................................................... 840
P-20 ENGINE OIL PRESSURE DROP CAUTION LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001]................................................................................................................................................................. 841
P-21 ENGINE OIL PRESSURE DROP CAUTION LAMP STAYS LIGHTED UP........................................................................................................................................................................................................... 842
P-22 EXHAUST BRAKE PILOT LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001].............................................................................................................................................................................. 843
P-23 EXHAUST BRAKE PILOT LAMP STAYS LIGHTED UP........................................................................................................................................................................................................................ 844
P-24 CHARGING CIRCUIT ABNORMALITY CAUTION LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001]............................................................................................................................................................. 845
P-25 CHARGING CIRCUIT ABNORMALITY CAUTION LAMP STAYS LIGHTED UP....................................................................................................................................................................................................... 846
P-26 TRANSMISSION FILTER CLOGGING CAUTION LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001]............................................................................................................................................................. 847
P-27 TRANSMISSION FILTER CLOGGING CAUTION LAMP STAYS LIGHTED UP....................................................................................................................................................................................................... 848
P-28 BRAKE STROKE CAUTION LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001]............................................................................................................................................................................. 849
P-29 BRAKE STROKE CAUTION LAMP STAYS LIGHTED UP....................................................................................................................................................................................................................... 850
P-30 PREHEATING SWITCH PILOT LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001].......................................................................................................................................................................... 851
P-31 PREHEATING SWITCH PILOT LAMP STAYS LIGHTED UP.................................................................................................................................................................................................................... 852
P-32 TILT WARNING LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001]..................................................................................................................................................................................... 853
P-33 TILT WARNING LAMP STAYS LIGHTED UP............................................................................................................................................................................................................................... 854
P-34 BODY FLOAT (EXCEPT FLOAT) PILOT LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001].................................................................................................................................................................. 855
P-35 BODY FLOAT (EXCEPT FLOAT) PILOT LAMP STAYS LIGHTED UP............................................................................................................................................................................................................ 856
P-36 REAR BRAKE PILOT LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001]................................................................................................................................................................................. 857
P-37 REAR BRAKE PILOT LAMP STAYS LIGHTED UP........................................................................................................................................................................................................................... 858
P-38 PARKING BRAKE PILOT LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001].............................................................................................................................................................................. 859
P-39 PARKING BRAKE PILOT LAMP STAYS LIGHTED UP........................................................................................................................................................................................................................ 860
P-40 MAINTENANCE CAUTION LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001].............................................................................................................................................................................. 861
P-41 MAINTENANCE CAUTION LAMP STAYS LIGHTED UP........................................................................................................................................................................................................................ 862
P-42 STEERING OIL TEMPERATURE CAUTION LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001]................................................................................................................................................................. 863
P-43 STEERING OIL TEMPERATURE CAUTION LAMP STAYS LIGHTED UP........................................................................................................................................................................................................... 864
P-44 DIFFERENTIAL LOCK PILOT LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001].......................................................................................................................................................................... 865
P-45 DIFFERENTIAL LOCK PILOT LAMP STAYS LIGHTED UP.................................................................................................................................................................................................................... 866
P-46 HIGH BEAM DISPLAY DOES NOT LIGHT UP.............................................................................................................................................................................................................................. 867
P-47 TURN SIGNAL LAMP (RIGHT) DOES NOT LIGHT UP....................................................................................................................................................................................................................... 869
P-48 TURN SIGNAL LAMP (LEFT) DOES NOT LIGHT UP........................................................................................................................................................................................................................ 870
P-49 LAMP CHECK SWITCH DOES NOT WORK.................................................................................................................................................................................................................................. 871
P-50 AISS SWITCH DOES NOT WORK........................................................................................................................................................................................................................................ 872
P-51 EXHAUST BRAKE SWITCH DOES NOT WORK............................................................................................................................................................................................................................... 873
P-52 MODE CHANGE SWITCH (1) DOES NOT WORK............................................................................................................................................................................................................................. 874
P-53 MODE CHANGE SWITCH (2) DOES NOT WORK............................................................................................................................................................................................................................. 875
P-54 KPH/MPH SPEEDOMETER UNIT SELECTOR DOES NOT WORK.................................................................................................................................................................................................................. 876
P-55 DEFECTIVE OPERATION OF ALL SWITCH INPUTS......................................................................................................................................................................................................................... 877
P-56 MONITOR PANEL DETECTS SERVICE CODES [A014] OR [A019]............................................................................................................................................................................................................. 878
P-57 MONITOR PANEL DETECTS SERVICE CODE [A015]........................................................................................................................................................................................................................ 879
P-58 MONITOR PANEL DETECTS SERVICE CODE [A011]........................................................................................................................................................................................................................ 880
P-59 MONITOR PANEL DETECTS SERVICE CODE [A012]........................................................................................................................................................................................................................ 880
P-60 MONITOR PANEL DETECTS SERVICE CODE [A000]........................................................................................................................................................................................................................ 880
TROUBLESHOOTING OF PMC SYSTEM (M MODE).................................................................................................................................................................................................................................... 881
PMC RELATED ELECTRIC CIRCUIT DIAGRAM.................................................................................................................................................................................................................................. 883
M-1 PMC DOES NOT WORK................................................................................................................................................................................................................................................. 885
M-2 E002 [0.2:FLASHES] FAILURE IN NV RAM DATA IS DISPLAYED............................................................................................................................................................................................................ 886
M-3 E002 [0.2:FLASHES] DROP IN BATTERY DIRECT POWER SOURCE VOLTAGE IS DISPLAYED....................................................................................................................................................................................... 887
M-4 E003 [0.3:FLASHES] ABNROMALITY IN CONNECTOR CONNECTION IS DISPLAYED............................................................................................................................................................................................... 889
M-5 E011 [1.1:FLASHES] DISCONNECTION IN GSP COMMUNICATIONS IS DISPLAYED............................................................................................................................................................................................... 890
M-5 E012 [1.2:FLASHES] ABNORMALITY IN GSP COMMUNICATIONS IS DISPLAYED................................................................................................................................................................................................. 890
M-6 E013 [1.3:FLASHES] DISCONNECTION IN MOM COMMUNICATIONS IS DISPLAYED............................................................................................................................................................................................... 891
M-6 E014 [1.4:FLASHES] ABNORMALITY IN MOM COMMUNICATIONS IS DISPLAYED................................................................................................................................................................................................. 891
M-7 E015 [1.5:FLASHES] DISCONNECTION IN TMS COMMUNICATIONS IS DISPLAYED............................................................................................................................................................................................... 892
M-7 E016 [1.6:FLASHES] ABNORMALITY IN TMS COMMUNICATIONS IS DISPLAYED................................................................................................................................................................................................. 892
M-8 E017 [1.7:FLASHES] DISCONNECTION IN CENSE COMMUNICATIONS IS DISPLAYED............................................................................................................................................................................................. 892
M-8 E018 [1.8:FLASHES] ABNORMALITY IN CENSE COMMUNICATIONS IS DISPLAYED............................................................................................................................................................................................... 892
M-9 E026 [2.6:FLASHES] COMMUNICATIONS ABNORMALITY 1 IS DISPLAYED...................................................................................................................................................................................................... 893
M-9 E027 [2.7:FLASHES] COMMUNICATIONS ABNORMALITY 2 IS DISPLAYED...................................................................................................................................................................................................... 893
M-9 E028 [2.8:FLASHES] COMMUNICATIONS ABNORMALITY 3 IS DISPLAYED...................................................................................................................................................................................................... 893
M-9 E029 [2.9:FLASHES] COMMUNICATIONS ABNORMALITY 4 IS DISPLAYED...................................................................................................................................................................................................... 893
M-9 E02A [2.A:FLASHES] COMMUNICATIONS ABNORMALITY 5 IS DISPLAYED...................................................................................................................................................................................................... 893
M-10 E035 [3.5:FLASHES] ABNORMALITY IN IDLE VALIDATION IS DISPLAYED................................................................................................................................................................................................... 895
M-11 E041 [4.1:FLASHES] SHORT CIRCUIT WITH GROUND/DISCONNECTION IN SUSPENSION PRESSURE SENSOR (RIGHT) SYSTEM IS DISPLAYED............................................................................................................................................. 897
M-11 E042 [4.2:FLASHES] SHORT CIRCUIT WITH GROUND/DISCONNECTION IN SUSPENSION PRESSURE SENSOR (LEFT) SYSTEM IS DISPLAYED.............................................................................................................................................. 897
M-11 E043 [4.3:FLASHES] SHORT CIRCUIT IN SUSPENSION PRESSURE SENSOR (RIGHT) SYSTEM IS DISPLAYED....................................................................................................................................................................... 897
M-11 E044 [4.4:FLASHES] SHORT CIRCUIT IN SUSPENSION PRESSURE SENSOR (LEFT) SYSTEM IS DISPLAYED........................................................................................................................................................................ 897
M-12 E054 [5.4:FLASHES] DISCONNECTION IN ACCELERATOR SIGNAL SYSTEM IS DISPLAYED....................................................................................................................................................................................... 898
M-13 E055 [5.5:FLASHES] SHORT CIRCUIT IN ACCELERATOR CELL SIGNAL SYSTEM IS DISPLAYED.................................................................................................................................................................................. 899
M-14 E056 [5.6:FLASHES] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED........................................................................................................................................................................................ 900
M-15 E057 [5.7:FLASHES] ABNORMALITY IN INPUT SHAFT SPEED SENSOR SYSTEM IS DISPLAYED................................................................................................................................................................................... 901
M-16 E058 [5.8:FLASHES] ABNORMALITY IN TRAVEL SPEED SENSOR (TRANSMISSION OUTPUT SHAFT SPEED SENSOR) IS DISPLAYED...................................................................................................................................................... 902
M-17 E0A1 [A.1:FLASHES] WHEN ENGINE IS NOT RUNNING,DROP IN BRAKE OIL LEVEL IS DISPLAYED............................................................................................................................................................................... 903
M-18 E0A2 [A.2:FLASHES] WHEN ENGINE IS NOT RUNNING,DROP IN RETARDER OIL LEVEL IS DISPLAYED............................................................................................................................................................................ 904
M-19 E0A3 [A.3:FLASHES] WHEN ENGINE IS NOT RUNNING,DROP IN HYDRAULIC OIL LEVEL IS DISPLAYED........................................................................................................................................................................... 905
M-20 E0A6 [A.6:FLASHES] WHEN ENGINE IS RUNNING,RETARDER FILTER CLOGGED IS DISPLAYED................................................................................................................................................................................... 906
M-21 E0A7 [A.7:FLASHES] WHEN ENGINE IS RUNNING,FULL-FLOW FILTER CLOGGED IS DISPLAYED.................................................................................................................................................................................. 907
M-22 E0A8 [A.8:FLASHES] WHEN ENGINE IS RUNNING,HYDRAULIC FILTER CLOGGED IS DISPLAYED.................................................................................................................................................................................. 908
M-23 E0b2 [b.2:FLASHES] AT NEUTRAL,RIHGT RETARDER BRAKE DISC WEAR IS DISPLAYED........................................................................................................................................................................................ 909
M-24 E0b3 [b.3:FLASHES] AT NEUTRAL,LEFT RETARDER BRAKE DISC WEAR IS DISPLAYED......................................................................................................................................................................................... 910
M-25 E0b4 [b.4:FLASHES] WHEN ENGINE IS NOT RUNNING,DROP IN BATTERY ELECTROLYTE LEVEL IS DISPLAYED..................................................................................................................................................................... 911
M-26 E0b5 [b.5:FLASHES] WHEN ENGINE IS NOT RUNNING, DROP IN ENGINE OIL LEVEL IS DISPLAYED............................................................................................................................................................................. 912
M-27 E0b6 [b.6:FLASHES] WHEN ENGINE IS RUNNING,AIR CLEANER CLOGGED IS DISPLAYED....................................................................................................................................................................................... 913
M-28 E0C1 [C.1:FLASHES] ABNORMALITY IN NETWORK SYSTEM IS DISPLAYED.................................................................................................................................................................................................... 914
M-28 E0C2 [C.2:FLASHES] ABNORMALITY IN MODEL SELECTION DATA IS DISPLAYED.............................................................................................................................................................................................. 914
M-29 E0C3 [C.3:FLASHES] ABNORMALITY IN TRAVEL SPEED COMPENSATION DATA IS DISPLAYED.................................................................................................................................................................................... 916
M-30 SETTING OF PMC DIPSWITCHES....................................................................................................................................................................................................................................... 918
M-101 MOM DISPLAY IS NOT GIVEN........................................................................................................................................................................................................................................ 919
M-102 MOM DISPLAY IS GOES UT.......................................................................................................................................................................................................................................... 920
M-103 4-DIGIT ERROR CODE AND ERROR MESSAGE ARE DISPLAYED ON MOM....................................................................................................................................................................................................... 921
M-104 MOM TIME DISPLAY IS SLOW,WARNING DISPLAY SHOWS DEFECTIVE OPERATION OF CLOCK IC,OR WARNING DISPLAY SHOWS DROP IN BATTERY VOLTAGE................................................................................................................................. 922
M-105 (DROP IN BATTERY VOLTAGE) WARNING IS DISPLAYED.................................................................................................................................................................................................................. 924
TROUBLESHOOTING OF ABS/ASR SYSTEM (OP).................................................................................................................................................................................................................................... 925
TROUBLESHOOTING FLOWCHART............................................................................................................................................................................................................................................. 926
FOR MACHINES WITH ABS INSTALLED INDEPENDENTLY..................................................................................................................................................................................................................... 926
FOR MACHINES WITH ABS/ASR INSTALLED............................................................................................................................................................................................................................... 927
METHOD OF DELETING ECU TROUBLE DATA FROM MEMORY....................................................................................................................................................................................................................... 928
PROCEDURE FOR DELETING TROUBLE DATA FROM MEMORY................................................................................................................................................................................................................... 928
METHOD OF TROUBLESHOOTING USING SELF-DIAGNOSTIC FUNCTION OF ECU....................................................................................................................................................................................................... 929
INDEX (TROUBLESHOOTING CODE)...................................................................................................................................................................................................................................... 930
SYSTEM CHECK SHEET FOR USING SYSTEM CHECKER........................................................................................................................................................................................................................... 932
W-1 WARNING LAMP DOES NOT LIGHT UP.................................................................................................................................................................................................................................... 940
I-1 ASR INFORMATION SWITCH DOES NOT GO OUT............................................................................................................................................................................................................................ 941
ASR-1 FAILURE IN ASR CONTROL VALVE (ONLY MACHINES WITH ABS/ASR INSTALLED)............................................................................................................................................................................................. 942
ASR-2................................................................................................................................................................................................................................................................. 943
ABS-1 FAILURE INSIDE ECU.............................................................................................................................................................................................................................................. 944
ABS-2 FAILURE IN FRONT RIGHT PRESSURE CONTROL VALVE................................................................................................................................................................................................................... 945
ABS-3 FAILURE IN FRONT LEFT PRESSURE CONTROL VALVE.................................................................................................................................................................................................................... 946
ABS-4 FAILURE IN REAR LEFT PRESSURE CONTROL VALVE..................................................................................................................................................................................................................... 947
ABS-5 FAILURE IN REAR RIGHT PRESSURE CONTROL VALVE.................................................................................................................................................................................................................... 948
ABS-6 FAILURE IN FRONT RIGHT WHEEL SPEED SENSOR....................................................................................................................................................................................................................... 949
ABS-10 ABNORMALITY IN FRONT RIGHT WHEEL SPEED SENSOR OUTPUT........................................................................................................................................................................................................... 949
ABS-7 FAILURE IN FRONT LEFT WHEEL SPEED SENSOR........................................................................................................................................................................................................................ 950
ABS-11 ABNORMALITY IN FRONT LEFT WHEEL SPEED SENSOR OUTPUT............................................................................................................................................................................................................ 950
ABS-8 FAILURE IN REAR WHEEL SPEED SENSOR.............................................................................................................................................................................................................................. 951
ABS-12 ABNORMALITY IN REAR LEFT WHEEL SPEED SENSOR OUTPUT............................................................................................................................................................................................................. 951
ABS-9 FAILURE IN REAR RIGHT WHEEL SPEED SENSOR........................................................................................................................................................................................................................ 952
ABS-13 ABNORMALITY IN REAR RIGHT WHEEL SPEED SENSOR OUTPUT............................................................................................................................................................................................................ 952
ABS-14 FAILURE IN VALVE RELAY (VR2)................................................................................................................................................................................................................................... 953
ABS-15 FAILURE IN VALVE RELAY (VR1)................................................................................................................................................................................................................................... 954
ABS-16 FAILURE IN VALVE RELAY (VR2)................................................................................................................................................................................................................................... 955
ABS-17 FAILURE IN VALVE RELAY (VR1)................................................................................................................................................................................................................................... 956
ABS-18 ABNORMALITY IN POWER SOURCE VOLTAGE............................................................................................................................................................................................................................ 957
TROUBLESHOOTING FOR MAINTENANCE MONITOR SYSTEM............................................................................................................................................................................................................................ 958
MM-1 MAINTENANCE MONITOR DOES NOT WORK................................................................................................................................................................................................................................ 959
a) WHEN NOTHING WORKS............................................................................................................................................................................................................................................. 959
b) WHEN CHECK DISPLAY DOES NOT WORK............................................................................................................................................................................................................................... 960
MM-2 WHEN ENGINE IS STOPPED,ENGINE OIL LEVEL DISPLAY FLASHES.......................................................................................................................................................................................................... 961
MM-3 WHEN ENGINE IS STOPPED,TRANSMISSION OIL LEVEL DISPLAY FLASHES.................................................................................................................................................................................................... 962
MM-4 WHEN ENGINE IS STOPPED,HYDRAULIC OIL LEVEL DISPLAY FLASHES....................................................................................................................................................................................................... 963
MM-5 WHEN ENGINE IS STOPPED,RETARDER OIL LEVEL DISPLAY FLASHES........................................................................................................................................................................................................ 963
MM-6 WHEN ENGINE IS STOPPED,BRAKE OIL LEVEL DISPLAY FLASHES........................................................................................................................................................................................................... 964
MM-7 WHEN ENGINE IS STOPPED,BATTERY ELECTROLYTE LEVEL DISPLAY FLASHES................................................................................................................................................................................................. 965
MM-8 AT NEUTRAL,RETARDER WEAR DISPLAY FLASHES......................................................................................................................................................................................................................... 966
MM-9 WHEN ENGINE IS RUNNING,AIR CLEANER CLOGGING DISPLAY FLASHES...................................................................................................................................................................................................... 967
MM-10 WHEN ENGINE IS RUNNING,FULL-FLOW FILTER CLOGGING DISPLAY FLASHES................................................................................................................................................................................................ 968
MM-11 WHEN ENGINE IS RUNNING,TRANSMISSION FILTER CLOGGING DISPLAY FLASHES............................................................................................................................................................................................. 969
MM-12 WHEN ENGINE IS RUNNING,HYDRAULIC FILTER CLOGGING DISPLAY FLASHES................................................................................................................................................................................................ 970
MM-13 WHEN ENGINE IS RUNNING,RETARDER FILTER CLOGGING DISPLAY FLASHES................................................................................................................................................................................................. 971
MM-14 MAINTENANCE TIMER DOES NOT WORK................................................................................................................................................................................................................................. 972
MM-15 MAINTENANCE TIMER IS NOT 0H OR BELOW,BUT MAINTENANCE ITEM LIGHTS UP............................................................................................................................................................................................. 972
MM-16 ABNROMALITY IN SWITCH........................................................................................................................................................................................................................................... 973
a) CONFIRMATION SWITCH FOR OIL OR FILTER REPLACEMENT TIME DOES NOT WORK........................................................................................................................................................................................... 973
b) REPLACEMENT SWITCH,MISOPERATION CANCEL SWITCH DO NOT WORK...................................................................................................................................................................................................... 973
MM-17 NIGHT LIGHTING DOES NOT LIGHT UP................................................................................................................................................................................................................................ 974
TROUBLESHOOTING FOR AUTOMATIC SPIN REGULATOR (ASR-โ
ก) SYSTEM (AS MODE)..................................................................................................................................................................................................... 975
OUTLINE............................................................................................................................................................................................................................................................... 976
AS-1 FAILURE CODE 0.1 "ABNORMALITY IN POWER SOURCE VOLTAGE" IS DISPLAYED.............................................................................................................................................................................................. 978
AS-2 FAILURE CODE 1.0 "DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM" IS DISPLAYED...................................................................................................................................................................................... 979
AS-3 FAILURE CODE 1.1 "DISCONNECTION IN RR WHEEL SPEED SENSOR" IS DISPLAYED........................................................................................................................................................................................... 980
AS-4 FAILURE CODE 1.2 "DISCONNECTION IN RL WHEEL SPEED SENSOR" IS DISPLAYED........................................................................................................................................................................................... 981
AS-5 FAILURE CODE 1.3 "DISCONNECTION IN TRANSMISSION OUTPUT SHAFT SPEED SENSOR SYSTEM" IS DISPLAYED................................................................................................................................................................... 982
AS-6 FAILURE CODE 1.6 "FAILURE IN STEERING ANGLE SENSOR" IS DISPLAYED................................................................................................................................................................................................. 983
AS-7 FAILURE CODE 1.7 "FAILURE IN ACCELERATOR SIGNAL SYSTEM" IS DISPLAYED............................................................................................................................................................................................. 984
AS-8 FAILURE CODE 4.3 "DISCONNECTION ON ARSC CAUTION LAMP SYSTEM" IS DISPLAYED........................................................................................................................................................................................ 985
AS-9 FAILURE CODE 4.5 "DISCONNECTION IN PANEL CAUTION LAMP AND BUZZER SYSTEM" IS DISPLAYED............................................................................................................................................................................ 986
AS-10 FAILURE CODE 5.3 "SHORT CIRCUIT WITH GROUND IN ARSC CAUTION LAMP SYSTEM" IS DISPLAYED........................................................................................................................................................................... 987
AS-11 FAILURE CODE 5.5 "SHORT CIRCUIT WITH GROUND IN PANEL CAUTION LAMP AND BUZZER SYSTEM" IS DISPLAYED............................................................................................................................................................... 988
AS-12 FAILURE CODE 6.0 "FAILURE IN ENGINE SPEED SENSOR SYSTEM" IS DISPLAYED........................................................................................................................................................................................... 989
AS-13 FAILURE CODE 6.1 "FAILURE IN RR WHEEL SPEED SENSOR SYSTEM" IS DISPLAYED......................................................................................................................................................................................... 990
AS-14 FAILURE CODE 6.2 "FAILURE IN RL WHEEL SPEED SENSOR SYSTEM" IS DISPLAYED......................................................................................................................................................................................... 991
AS-15 FAILURE CODE 8.0 "FAILURE IN PRESSURE CONTROL VALVE (L.H.) SYSTEM:PRESSURE CONTROL VALVE (L.H.)DOES NOT OPEN" IS DISPLAYED...................................................................................................................................... 992
AS-16 FAILURE CODE 8.1 "SHORT CIRCUIT WITH CHASSIS GROUND IN PRESSURE CONTROL VALVE (R.H.) SYSTEM" IS DISPLAYED....................................................................................................................................................... 993
AS-17 FAILURE CODE 8.2 "SHORT CIRCUIT WITH CHASSIS GROUND IN PRESSURE CONTROL VALVE (L.H.) SYSTEM" IS DISPLAYED....................................................................................................................................................... 994
AS-18 FAILURE CODE 8.3 "DISCONNECTION IN PRESSURE CONTROL VALVE (R.H.) SYSTEM" IS DISPLAYED........................................................................................................................................................................... 995
AS-19 FAILURE CODE 8.4 "DISCONNECTION IN PRESSURE CONTROL VALVE (L.H.) SYSTEM" IS DISPLAYED........................................................................................................................................................................... 996
AS-20 FAILURE CODE 8.5 "FAILURE IN PRESSURE CONTROL VALVE (R.H.) SYSTEM:PRESSURE CONTROL VALVE (R.H.) DOES NOT CLOSE" IS DISPLAYED.................................................................................................................................... 997
AS-21 FAILURE CODE 8.6 "FAILURE IN PRESSURE CONTROL VALVE (L.H.) SYSTEM:PRESSURE CONTROL VALVE (L.H.) DOES NOT CLOSE" IS DISPLAYED.................................................................................................................................... 998
AS-22 FAILURE CODE 8.7 "FAILURE IN PRESSURE CONTROL VALVE (R.H.) SYSTEM:PRESSURE CONTROL VALVE (R.H.) DOES NOT OPEN" IS DISPLAYED..................................................................................................................................... 999
AS-23 FAILURE CODE 8.9 "SHORT CIRCUIT WITH CHASSIS GROUND IN PRESSURE SWITCH VALVE SYSTEM" IS DISPLAYED...............................................................................................................................................................1000
AS-24 FAILURE CODE 9.0 "DISCONNECTION IN PRESSURE SWITCH VALVE SYSTEM" IS DISPLAYED...................................................................................................................................................................................1001
AS-25 FAILURE CODE 9.1 "FAILURE IN PRESSURE SWITCH VALVE SYSTEM:VALVE DOES NOT CLOSE" IS DISPLAYED....................................................................................................................................................................1002
AS-26 FAILURE CODE 9.2 "FAILURE IN PRESSURE SWITCH VALVE SYSTEM:VALVE DOES NOT OPEN" IS DISPLAYED.....................................................................................................................................................................1003
AS-101 NOTHING IS DISPLAYED ON DISPLAY WINDOW OF CONTROLLER...........................................................................................................................................................................................................1004
AS-102 FAILURE CODE IS KEPT CLEARED ("--" IS ALWAYS DISPLAYED IN DISPLAY WINDOW OF CONTROLLER) OR CANNOT BE CLEARED...................................................................................................................................................1005
AS-103 ANOTHER CONTROLLER HAS A FAILURE...............................................................................................................................................................................................................................1006
AS-104 MONITOR LAMP (BUZZER) STAYS ON (OR OFF)........................................................................................................................................................................................................................1007
AS-105 DISCONNECTION IN SWITCH SYSTEM OF ASR SYSTEM...................................................................................................................................................................................................................1008
AS-106 SHORT CIRCUIT WITH CHASSIS GROUND IN SWITCH SYSTEM OF ASR SYSTEM...............................................................................................................................................................................................1009
AS-107 ASR WORKING LAMP DOES NOT LIGHT UP.............................................................................................................................................................................................................................1010
AS-108 ASR WORKING LAMP REMAINS LIT...................................................................................................................................................................................................................................1012
VHMS MACHINE HEALTH DIAGNOSIS SYSTEM (OP).................................................................................................................................................................................................................................1014
1.BSAIC PRECAUTIONS...................................................................................................................................................................................................................................................1015
1-1. OPERAION, SAFETY, INSPECITON AND MAINTENANCE OF MACHINE .....................................................................................................................................................................................................1015
1-2. OPERATION OF MONITORING SYSTEM...............................................................................................................................................................................................................................1015
1-3. CONSTANT POWER SUPPLY (BATERY DIRECT POWER SUPPLY)...........................................................................................................................................................................................................1015
1-4. PRECAUTIONS AT THE TIME OF TURNING ON THE POWER FOR VHMS.....................................................................................................................................................................................................1016
1-5. PRECAUTIONS AT THE TIME OF REPLACING VHMS AND TRANSMISSION CONTROLLER........................................................................................................................................................................................1016
1-6. OPERATION OF COMMUNICATION (ORB...ORB COMMUNICATION) CONTROLLER..............................................................................................................................................................................................1017
2. OVERVIEW...........................................................................................................................................................................................................................................................1018
2-1. APPLICABLE MODEL.............................................................................................................................................................................................................................................1018
2-2. BASIC CONFIGURATION (1) AND (2)..............................................................................................................................................................................................................................1018
2-3. INSTALLATION DRAWING.........................................................................................................................................................................................................................................1021
3. STRUCTURE AND FUNCTION.............................................................................................................................................................................................................................................1023
3-1. VHMS CONTROLLER..............................................................................................................................................................................................................................................1023
3-2. BLOW-BY GAS SENSOR...........................................................................................................................................................................................................................................1023
3-3. ENGINE OIL TEMPERAUTRE SENSOR................................................................................................................................................................................................................................1024
3-4. AMPLIFIER FOR EXHAUST GAS TEMPERATURE SENSOR.................................................................................................................................................................................................................1025
3-5. COMMUNICATION (ORB...ORB COMMUNICATION) CONTROLLER/ANTENNA...................................................................................................................................................................................................1025
4. TROUBLESHOOTING....................................................................................................................................................................................................................................................1027
4-1. TROUBLESHOOTING EQUIPMENT LIST...............................................................................................................................................................................................................................1027
4-2. CONNECTOR TYPE AND MOUNTING LOCATIONS........................................................................................................................................................................................................................1028
4-3. CONNECTOR ARRANGEMENT DIAGRAM................................................................................................................................................................................................................................1029
4-4. ELECTRICAL CIRCUIT DIAGRAM...................................................................................................................................................................................................................................1034
4-5. ERROR CODE LIST..............................................................................................................................................................................................................................................1035
4-6. STANDARD VALUE TABLE FOR ELECTRICAL PARTS....................................................................................................................................................................................................................1036
4-7. TROUBLE PHENOMENA LIST.......................................................................................................................................................................................................................................1037
5. DISASSEMBLY AND ASSEMBLY...........................................................................................................................................................................................................................................1049
5-1. REMOVAL AND INTRALLATION OF VHMS CONTROLLER..................................................................................................................................................................................................................1049
5-2. REMOVAL AND INSTALLATION OF BLOW-BY GAS SENSOR...............................................................................................................................................................................................................1050
5-3. REMOVAL AND INSTALLATION OF BREATHER.........................................................................................................................................................................................................................1050
5-4. REMOVAL AND INSTALLATION OF ENGINE OIL TEMPERATURE SENSOR....................................................................................................................................................................................................1051
5-5. REMOVAL AND INSTALLATION OF EXHAUST GAS TEMPERATURE SENSOR...................................................................................................................................................................................................1051
5-6. REMOVAL AND INSTALLATION OF EXHAUST GAS TEMPERATURE AMPLIFIER................................................................................................................................................................................................1052
5-7. REMOVAL AND INSTALLATION OF SNAPSHOT SWITCH..................................................................................................................................................................................................................1052
5-8. REMOVAL AND INSTALLATION OF COMMUNICATION (ORB ...ORG COMMUNICATION) CONTROLER AND ANTENNA...................................................................................................................................................................1053
6. SETTING OF VHMS CONTROLLER.........................................................................................................................................................................................................................................1054
6-1. SETTING OF CHMS CONTROLLER...................................................................................................................................................................................................................................1054
6-2. SETTING ITEM.................................................................................................................................................................................................................................................1054
6-3. SRTTING FLOW (OUTLINE).......................................................................................................................................................................................................................................1054
6-4. CHECK OF OPERATION AND PERFORMANCE...........................................................................................................................................................................................................................1055
6-5. DATA COLLECTION..............................................................................................................................................................................................................................................1055
7. DATA RECOVERY AND TRANSMISSION.....................................................................................................................................................................................................................................1056
7-1. DATA RECOVERY................................................................................................................................................................................................................................................1056
8. INSPECTION AND MAINTEANCE..........................................................................................................................................................................................................................................1061
8-1. INSPECTION TIMING: INSPECTION AND MAINTENANCE TIMING OF MACHINE..............................................................................................................................................................................................1061
8-2. INSPECTION ITEM..............................................................................................................................................................................................................................................1061
9. REPLACEMENT OF PARTS...............................................................................................................................................................................................................................................1062
9-1. WHEN THE CHMS CONTROLLER IS REPLACED.........................................................................................................................................................................................................................1062
9-2. WHEN COMMUNICATION CONTROLLER IS REPLACED....................................................................................................................................................................................................................1062
PROCEDURE โ
FOR INITIAL SETUP OF VHMS.................................................................................................................................................................................................................................1063
PROCEDURE โ
ก FOR OPENING ORBCOMM SERVICE...............................................................................................................................................................................................................................1065
30 DISASSEMBLY AND ASSEMBLY.......................................................................................................................................................................................................................................................1069
METHOD OF USING MANUAL........................................................................................................................................................................................................................................................1071
PRECAUTIONS WHEN CARRYING OUT OPERATION.......................................................................................................................................................................................................................................1072
SPECIAL TOOL LIST.............................................................................................................................................................................................................................................................1074
STARING MOTOR.................................................................................................................................................................................................................................................................1077
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1077
ALTERNATOR....................................................................................................................................................................................................................................................................1078
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1078
ENGINE OIL COOLER.............................................................................................................................................................................................................................................................1079
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1079
LEFT BANK FUEL INJECTION PUMP.................................................................................................................................................................................................................................................1080
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1080
RIGHT BANK FUEL INJECTION PUMP ASSEMBKY (WITHOUT GOVERNOR)....................................................................................................................................................................................................................1081
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1081
AIR COMPRESSOR................................................................................................................................................................................................................................................................1082
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1082
WATER PUMP....................................................................................................................................................................................................................................................................1083
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1083
AFTERCOOLER CORE..............................................................................................................................................................................................................................................................1084
REMOVAL...................................................................................................................................................................................................................................................................1084
INSTALLATION..............................................................................................................................................................................................................................................................1085
TURBOCHARGER..................................................................................................................................................................................................................................................................1086
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1086
NOZZLE HOLDER.................................................................................................................................................................................................................................................................1087
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1087
CYLINDER HEAD.................................................................................................................................................................................................................................................................1088
REMOVAL...................................................................................................................................................................................................................................................................1088
INSTALLATION..............................................................................................................................................................................................................................................................1089
EXHAUST BRAKE.................................................................................................................................................................................................................................................................1091
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1091
ENGINE........................................................................................................................................................................................................................................................................1092
REMOVAL...................................................................................................................................................................................................................................................................1092
INATALLATION..............................................................................................................................................................................................................................................................1096
ENGINE FRONT SEAL.............................................................................................................................................................................................................................................................1097
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1097
ENGINE REAR SEAL..............................................................................................................................................................................................................................................................1100
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1100
RADIATOR TORQUE CONVERTER COOLER..............................................................................................................................................................................................................................................1104
REMOVAL...................................................................................................................................................................................................................................................................1104
INSTALLATION..............................................................................................................................................................................................................................................................1105
BRAKE COOLER..................................................................................................................................................................................................................................................................1106
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1106
OUTPUT SHAFT..................................................................................................................................................................................................................................................................1107
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1107
DISASSEMBLY...............................................................................................................................................................................................................................................................1109
ASSEMBLY..................................................................................................................................................................................................................................................................1110
TORQUE CONVERTER, TRANSMISSION................................................................................................................................................................................................................................................1112
REMOVAL...................................................................................................................................................................................................................................................................1112
INSTALLATION..............................................................................................................................................................................................................................................................1114
PROCEDURE FOR CENTERING THE ENGINE ASSEMBLY AND TROQUE CONVERTER, TRANSMISSION ASSEMBLY.......................................................................................................................................................................................1115
TORQUE CONVERTER, CONTROL VALVE...............................................................................................................................................................................................................................................1116
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1116
DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................................................................................................1117
TORQUE CONVERTER AND TRANSMISSION.............................................................................................................................................................................................................................................1118
DISCONNECTION.............................................................................................................................................................................................................................................................1118
CONNECTION................................................................................................................................................................................................................................................................1119
TORQUE CONVERTER, PTO.........................................................................................................................................................................................................................................................1120
DISASSEMBLY...............................................................................................................................................................................................................................................................1120
ASSEMBLY..................................................................................................................................................................................................................................................................1126
TRANSMISSION..................................................................................................................................................................................................................................................................1132
DISASSEMBLY...............................................................................................................................................................................................................................................................1132
ASSEMBLY..................................................................................................................................................................................................................................................................1146
ECMV..........................................................................................................................................................................................................................................................................1163
DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................................................................................................1163
DIFFERENTIAL (FOR STANFARD DIFFERENTIAL)......................................................................................................................................................................................................................................1165
REMOVAL...................................................................................................................................................................................................................................................................1165
INSTALLATION..............................................................................................................................................................................................................................................................1166
DISASSEMBLY...............................................................................................................................................................................................................................................................1167
ASSEMBLY..................................................................................................................................................................................................................................................................1171
DIFFERENTIAL (WITH DIFFERENTIAL LOCK).........................................................................................................................................................................................................................................1180
REMOVAL...................................................................................................................................................................................................................................................................1180
INSTALLATION..............................................................................................................................................................................................................................................................1181
DISASSEMBLY...............................................................................................................................................................................................................................................................1182
ASSEMBLY..................................................................................................................................................................................................................................................................1187
FRONT WHEEL...................................................................................................................................................................................................................................................................1197
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1197
REAR WHEEL....................................................................................................................................................................................................................................................................1198
REMOVAL...................................................................................................................................................................................................................................................................1198
INSTALLATION..............................................................................................................................................................................................................................................................1199
FRONT BRAKE CALIPER ..........................................................................................................................................................................................................................................................1200
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1200
DISASSEMBLY...............................................................................................................................................................................................................................................................1201
ASSEMBLY..................................................................................................................................................................................................................................................................1202
FRONT BRAKE CALIPER PAD.......................................................................................................................................................................................................................................................1204
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1204
FRONT WHEEL HUB...............................................................................................................................................................................................................................................................1205
DISASSEMBLY...............................................................................................................................................................................................................................................................1205
ASSEMBLY..................................................................................................................................................................................................................................................................1207
FINAL DRIVE CARRIER...........................................................................................................................................................................................................................................................1210
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1210
DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................................................................................................1211
FINAL DRIVE...................................................................................................................................................................................................................................................................1212
DISASSEMBLY...............................................................................................................................................................................................................................................................1212
ASSEMBLY..................................................................................................................................................................................................................................................................1214
REAR BRAKE....................................................................................................................................................................................................................................................................1216
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1216
REAR WHEEL BRAKE..............................................................................................................................................................................................................................................................1217
DISASSEMBLY...............................................................................................................................................................................................................................................................1217
ASSEMBLY..................................................................................................................................................................................................................................................................1218
PARKING BRAKE PAD.............................................................................................................................................................................................................................................................1220
REMOVAL...................................................................................................................................................................................................................................................................1220
INSTALLATION..............................................................................................................................................................................................................................................................1221
PARKING BRAKE CALIPER.........................................................................................................................................................................................................................................................1222
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1222
DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................................................................................................1223
FRONT SUSPENDION CYLINDER.....................................................................................................................................................................................................................................................1224
REMOVAL AND ISNTALLATION..................................................................................................................................................................................................................................................1224
DISASSEMBLY (STANDARD CYLINDER)...........................................................................................................................................................................................................................................1225
ASSEMBLY (STANDARD CYLINDER)..............................................................................................................................................................................................................................................1226
DISSASSEMBLY (CYLINDER WITH BUFFER RING)..................................................................................................................................................................................................................................1227
ASSEMBLY (CYLINDER WITH BUFFER RING)......................................................................................................................................................................................................................................1228
KING PIN......................................................................................................................................................................................................................................................................1230
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1230
VARIBLE DAMPING SELECTIOR VALVE ..............................................................................................................................................................................................................................................1231
DISASSEMBLY...............................................................................................................................................................................................................................................................1231
ASSEMBLY..................................................................................................................................................................................................................................................................1232
REAR SUSPENSION CYLINDER......................................................................................................................................................................................................................................................1233
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1233
DISASSEMBLY (STANDARD CYLINDER)...........................................................................................................................................................................................................................................1234
ASSEMBLY (STANDARD CYLINDER)..............................................................................................................................................................................................................................................1235
DISASSEMBLY (CYLINDER WITH BUFFER RING)...................................................................................................................................................................................................................................1236
ASSEMBLY (CYLINDERWITH BUFFER RING).......................................................................................................................................................................................................................................1237
AIR GOVERNOR..................................................................................................................................................................................................................................................................1238
REMOVAL AND INATALLATION..................................................................................................................................................................................................................................................1238
DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................................................................................................1239
BRAKE VALVE...................................................................................................................................................................................................................................................................1240
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1240
DISASSEMBLY...............................................................................................................................................................................................................................................................1241
ASSEMBLY..................................................................................................................................................................................................................................................................1243
PARKING VRAKE CHAMBER.........................................................................................................................................................................................................................................................1245
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1245
DISASSEMBLY...............................................................................................................................................................................................................................................................1246
ASSEMBLY..................................................................................................................................................................................................................................................................1247
REAR BRAKE VHAMBER............................................................................................................................................................................................................................................................1249
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1249
DISASSEMBLY...............................................................................................................................................................................................................................................................1250
ASSEMBLY..................................................................................................................................................................................................................................................................1254
FRONT BRAKE CHAMBER...........................................................................................................................................................................................................................................................1257
DISASSEMBLY...............................................................................................................................................................................................................................................................1257
ASSEMBLY..................................................................................................................................................................................................................................................................1259
SLACK ADJUSTER................................................................................................................................................................................................................................................................1261
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1261
DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................................................................................................1262
AIR DRIER (DESICCANT TYPE)....................................................................................................................................................................................................................................................1263
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1263
DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................................................................................................1264
BRAKE COLLING PUMP............................................................................................................................................................................................................................................................1281
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1281
STEERING, HOIST PUMP .........................................................................................................................................................................................................................................................1282
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1282
TORQUE CONVERTER, TRANSMISSION PUMP...........................................................................................................................................................................................................................................1283
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1283
EMERGENCY STEERING MOTOR PUMP.................................................................................................................................................................................................................................................1284
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1284
STEERING VALVE................................................................................................................................................................................................................................................................1285
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1285
DISASSEMBLY...............................................................................................................................................................................................................................................................1286
ASSEMBLY..................................................................................................................................................................................................................................................................1290
BRAKE CONTROL VALVE (BCV).....................................................................................................................................................................................................................................................1297
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1297
DEMAND VALVE..................................................................................................................................................................................................................................................................1298
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1298
DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................................................................................................1299
RELIEF VALVE..................................................................................................................................................................................................................................................................1300
DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................................................................................................1300
HOIST VALVE...................................................................................................................................................................................................................................................................1301
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1301
DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................................................................................................1302
STEERING CYLINDER.............................................................................................................................................................................................................................................................1304
REMOVAL AND INSTALATION...................................................................................................................................................................................................................................................1304
DISASSEMBLY...............................................................................................................................................................................................................................................................1305
ASSEMBLY..................................................................................................................................................................................................................................................................1307
HOIST CYLINDER................................................................................................................................................................................................................................................................1310
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1310
DISASSEMBLY...............................................................................................................................................................................................................................................................1311
ASSEMBLY..................................................................................................................................................................................................................................................................1312
BODY..........................................................................................................................................................................................................................................................................1313
REMOVAL...................................................................................................................................................................................................................................................................1313
INSTALLATION..............................................................................................................................................................................................................................................................1314
CONTROLLER....................................................................................................................................................................................................................................................................1315
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1315
AIR CONITIONER COMPRESSOR.....................................................................................................................................................................................................................................................1316
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1316
RECEIVER TAKE.................................................................................................................................................................................................................................................................1317
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1317
AIR CONDITIONER CONDENSER.....................................................................................................................................................................................................................................................1318
REMOVAL AND INSTALLATION..................................................................................................................................................................................................................................................1318
40 MAINTENANCE STANDARD...........................................................................................................................................................................................................................................................1319
OUTPUT SHAFT..................................................................................................................................................................................................................................................................1320
TURQUE CONVERTER VALVE........................................................................................................................................................................................................................................................1321
TORQUE CONVERTER..............................................................................................................................................................................................................................................................1322
TRANSMISSION..................................................................................................................................................................................................................................................................1324
ECMV (ELECTRONIC CONTROL MODULATION VALVE)....................................................................................................................................................................................................................................1329
FRONT AXLE....................................................................................................................................................................................................................................................................1330
FRONT AXLE (WITH ABS/ASR) (IF EQUIPPED).......................................................................................................................................................................................................................................1332
REAR AXLE SUPPORT (HD785-5)...................................................................................................................................................................................................................................................1333
REAR AXLE SUPPORT (HD985-5)...................................................................................................................................................................................................................................................1334
DIFFERENTIAL..................................................................................................................................................................................................................................................................1335
FINAL DRIVE (HD785-5).........................................................................................................................................................................................................................................................1337
FINAL DRIVE (HD985-5).........................................................................................................................................................................................................................................................1340
FRONT BRAKE...................................................................................................................................................................................................................................................................1342
REAR BRAKE....................................................................................................................................................................................................................................................................1343
REAR BRAKE (WITH ABS/ASR) (IF EQUIPPED).......................................................................................................................................................................................................................................1345
PARKING BRAKE.................................................................................................................................................................................................................................................................1347
STEERING LINKAGE..............................................................................................................................................................................................................................................................1348
FRONT SUSPENSION CYLINDER.....................................................................................................................................................................................................................................................1350
REAR SUSPENSION CYLINDER......................................................................................................................................................................................................................................................1351
PARKING BRAKE CHAMBER.........................................................................................................................................................................................................................................................1352
SLACK ADJUSTER................................................................................................................................................................................................................................................................1353
HYDRAULIC PUMP (SAR-160) (FOR TORQUE CONVERTER AND TRANSMISSION)..............................................................................................................................................................................................................1354
HYDRAULIC PUMP (SAR4-180+180:FOR STEERING,WORK EQUIPMENT) (SAR4-285+285:FOR BRAKE COOLING)....................................................................................................................................................................................1355
DEMAND VALVE..................................................................................................................................................................................................................................................................1356
CROSS-OVER RELIEF VALVE.......................................................................................................................................................................................................................................................1356
HOIST VALVE...................................................................................................................................................................................................................................................................1357
STEERING CYLINDER.............................................................................................................................................................................................................................................................1358
HOIST CYLINDER................................................................................................................................................................................................................................................................1359
90 OTHERS.........................................................................................................................................................................................................................................................................1360
ELECTRICAL CIRCUIT DIAGRAM ...................................................................................................................................................................................................................................................1361
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH MECHANICAL GOVERNOR) (1/3)................................................................................................................................................................................................1361
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH MECHANICAL GOVERNOR) (2/3)................................................................................................................................................................................................1362
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH MECHANICAL GOVERNOR) (3/3)................................................................................................................................................................................................1363
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH ELECTRONIC GOVERNOR) (1/5)................................................................................................................................................................................................1364
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH ELECTRONIC GOVERNOR) (2/5)................................................................................................................................................................................................1365
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH ELECTRONIC GOVERNOR) (3/5)................................................................................................................................................................................................1366
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH ELECTRONIC GOVERNOR) (4/5)................................................................................................................................................................................................1367
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH ELECTRONIC GOVERNOR) (5/5)................................................................................................................................................................................................1368
ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (1/2)..........................................................................................................................................................................................................................1369
ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (2/2)..........................................................................................................................................................................................................................1370
ELECTRICAL CONTROL SYSTEM.....................................................................................................................................................................................................................................................1371
ELECTRICAL CIRCUIT DIAGRAM................................................................................................................................................................................................................................................1371
AUTOMATIC SHIFT CONTROL SYSTEM................................................................................................................................................................................................................................................1372
ELECTRICAL CIRCUIT DIAGRAM (1/2)..........................................................................................................................................................................................................................................1372
ELECTRICAL CIRCUIT DIAGRAM (2/2)..........................................................................................................................................................................................................................................1373
AUTOMATIC SUSPENSION SYSTEM...................................................................................................................................................................................................................................................1374
SYSTEM CIRCUIT DIAGRAM (1/2)..............................................................................................................................................................................................................................................1374
SYSTEM CIRCUIT DIAGRAM (2/2)..............................................................................................................................................................................................................................................1375
PAYLOAD METER (PRINTER TYPE) (OP).............................................................................................................................................................................................................................................1376
ELECTRICAL CIRCUIT DIAGRAM................................................................................................................................................................................................................................................1376
PAYLOAD METER โ
ก(CARD TYPE) (OP)...............................................................................................................................................................................................................................................1377
ELECTRICAL CIRCUIT DIAGRAM................................................................................................................................................................................................................................................1377
PMC SYSTEM (OP)...............................................................................................................................................................................................................................................................1378
ELECTRICAL CIRCUIT DIAGRAM (1/2)..........................................................................................................................................................................................................................................1378
ELECTRICAL CIRCUIT DIAGRAM (2/2)..........................................................................................................................................................................................................................................1380
ASR-โ
ก SYSTEM (OP).............................................................................................................................................................................................................................................................1380
ELECTRIAL CIRCUIT DIAGRAM.................................................................................................................................................................................................................................................1380
AIR CIRCUIT DIAGRAM.......................................................................................................................................................................................................................................................1381
ELECTRICAL CIRCUIT DIAGRAM....................................................................................................................................................................................................................................................1382
ENGINE CONTROL SYSTEM.....................................................................................................................................................................................................................................................1382
TRANSMISSION CONTROL SYSTEM...............................................................................................................................................................................................................................................1383
1. ELECTRIC GOVENOR SPECIFICATION.....................................................................................................................................................................................................................................1383
2. MECHANICAL GOVENOR SPECIFICATION...................................................................................................................................................................................................................................1384
4-4. ELECTRICAL CIRCUIT DIAGRAM...............................................................................................................................................................................................................................................1385DESCRIPTION:
KOMATSU HD785-5 HD985-5 SHOP MANUAL SEBM013916 – PDF DOWNLOAD
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
S.S 29/12/24
