Komatsu HD785-5, HD985-5 Dump Truck Service Repair Shop Manual - SEBM013912

This Complete Service Repair Workshop Manual PDF Download for the Komatsu Dump Truck HD785-5 & HD985-5 has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Komatsu HD785-5 Dump Truck
Serial Numbers : 4001 and up

Komatsu HD985-5 Dump Truck
Serial Numbers : 1021 and up


TABLE OF CONTENTS :

01 GENERAL
10 STRUCTURE AND FUNCTION
20 TESTING AND ADJUSTING
30 DISASSEMBLY AND ASSEMBLY
40 MAINTENANCE STANDARD
90 OTHERS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM013912
Total Pages : 1332


This 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 is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having PDF files instead of a hard-printed manual is that you can use the Search feature in Acrobat to find just what your looking for and just print out the exact pages you need or all manual.

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COVER
CONTENTS
01 GENERAL
GENERAL ASSEMBLY DRAWING
SPECIFICATIONS
WEIGHT TABLE
LIST OF LUBRICANT AND WATER

10 STRUCTURE AND FUNCTION
RADIATOR,TORQUE CONVERTER COOLER
BRAKE OIL COOLER
POWER TRAIN SKELETON
OUTPUT SHAFT (HD785-5)
OUTPUT SHAFT (HD985-5)
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT SCHEMATICS
TORQUE CONVERTER
TORQUE CONVERTER VLAVE
LOCKUP SOLENOID VALVE
TRANSMISSION
TRANSMISSION VALVE
ECMV
LUBRICATION RELIEF VALVE
FRONT AXLE (HD785-5)
FRONT AXLE (HD985-5)
REAR AXLE (HD785-5)
REAR AXLE (HD985-5)
DIFFERENTIAL
DIFFERENTIAL LOCK CONTROL
DIFFERENTIAL LOCK SOLENOID VALVE
FINAL DRIVE (HD785-5)
FINAL DRIVE (HD985-5)
FRONT BRAKE
REAR BRAKE
PARKING BRAKE
WHEELS (HD785-5)
WHEELS (HD985-5)
AXLE SUPPORT (HD785-5)
AXLE SUPPORT (HD985-5)
STEERING SYSTEM
STEERING WHEEL (HD785-5)
STEERING WHEEL (HD985-5)
STEERING LINKAGE
SUSPENSION SYSTEM
SUSPENSION CYLINDER
REAR SUSPENSION CYLINDER
AIR PIPING
AIR CIRCUIT DIAGRAM
AIR GOVERNOR
SAFETY VALVE
CHECK VALVE
DOUBLE CHECK VALVE
AUTO DRAIN VALVE
HAND BRAKE VALVE
BRAKE VALVE
EMERGENCY BRAKE CONTROL VALVE
PARKING BRAKE CONTROL VALVE
PARKING BRAKE PILOT VALVE
RELAY VLAVE
PARKING BRAKE RELAY VALVE
QUICK-RELEASE VALVE
PARKING BRAKE CHAMBER
RATIO VALVE (FOR FRONT BRAKE)
FRONT BRAKE CHAMBER
BRAKE CHAMBER
SLACK ADJUSTER
HYDRAULIC PIPING
HYDRALUIC CIRCUIT DIAGRAM
DUMP BODY CONTROL
HYDRAULIC TANK AND BRAKE COOLING OIL TANK (HD785-5)
HYDRAULIC TANK AND BRAKE COOLING OIL TANK (HD985-5)
BRAKE COOLING OIL CONTROL VALVE (BCV)
STEERING VALVE
DEMAND VALVE
HOIST VALVE
CROSSOVER RELIEF VALVE
STEERING CYLINDER
HOIST CYLINDER
ELECTRICAL CIRCUIT DIAGRAM
STOP LAMP SWITCH
EXHAUST BRAKE SWITCH
TILT SWITCH
FRONT BRAKE CUT-OFF VALVE
OVERRUN PREVENTION VALVE
EXHAUST BRAKE VALVE
HORN VALVE
PARKING BRAKE SWITCH
AIR CONDITIONER
PIPING DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM
REFRIGERANT CIRCUIT DIAGRAM
UNIT
RECEIVER DRYER
CONDENSER
COMPRESSOR
ENGINE CONTROL SYSTEM
SYSTEM DRAWING
ELECTRICAL CIRCUIT DIAGRAM
FUEL INJECTION PUMP ELECTRIC GOVERNOR
HYDRAULIC CIRCUIT DIAGRAM
AISS
SENSOR,SWITCHES
EXHAUST BRAKE
SYSTEM DIAGRAM
SYSTEM DIAGRAM
AUTOMATIC SHIFT CONTROL SYSTEM
SYSTEM DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM
TRANSMISSION CONTROLLER
CONNECTOR SIGNALS
SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFTING RANGES
AUTOMATIC GEAR SHIFTING LINE GRAPH
SHIFT LEVER SWITCH
SENSORS,SWITCHES
TRANSMISSION OIL TEMPERATURE SENSOR
FILL SWITCH
ACCELERATOR SENSOR
SHIFT LIMIT SWITCH
MODE SELECTOR SWITCH
SELF-DIAGNOSTIC FUNCTION
AUTOMATIC EMERGENCY STEERING SYSTEM
SYSTEM DIAGRAM
ELECTRIC CIRCUIT DIAGRAM
FLOW SWITCH
RELAY TIMER
AUTOMATIC SUSPENSION SYSTEM
SYSTEM DIAGRAM
STRUCTURE OF SYSTEM
SYSTEM CIRCUIT DIAGRAM
AUTOMATIC SUSPENSION MODE SELECTION CONTROL
SUSPENSION CONTROLLER
SENSOR,SWITCHES
STEERING ANGLE SENSOR
PRESSURE SENSOR
SELF-DIAGNOSTIC FUNCTION
PAYLOAD METER (PRINTER TYPE) (OP)
ELECTRICAL CIRCUIT DIAGRAM
PRINCIPLE OF CALCULATION
FEATURES OF EQUIPMENT
1. PAYLOAD METER
2. PRESSURE SENSOR
3. CLINOMETER
4. LAMP DRIVE RELAY
SELF-DIAGNOSTIC FUNCTION
PAYLOAD METER Ⅱ (CARD TYPE) (OP)
STRUCTURE OF SYSTEM
ELECTRICAL CIRCUIT DIAGRAM
PAYLOAD METER BLOCK DIAGRAM
PRINCIPLE OF MEASUREMENT
FEATURE OF EACH DEVICE
1.PAYLOAD METER Ⅱ
2.PRESSURE SENSOR
3.CLINOMETER
4.LAMP DRIVE RELAY
5.SELF-DIAGNOSTIC FUNCTION
MACHINE MONITOR SYSTEM
SYSTEM DRAWING
MONITOR PANEL DIAGRAM
MACHINE MONITOR NORMAL DISPLAY FUNCTONS
SELF-DIAGNOSTIC FUNCTION WHEN STARTING SWITCH IS OPERATED
TRAVEL SPEED COMPENSATION ROTARY SWITCH
SENSORS,SWITCHES
ENGINE SPEED SENSOR
TRANSMISSION SPEED SENSOR
ENGINE OIL PRESSURE
ENGINE WATER TEMPERATURE SENSOR
RETARDER OIL TEMPERATURE SENSOR
TORQUE CONVERTER OIL TEMPERATURE SENSOR
AIR PRESSURE SENSOR
FUEL LEVEL SENSOR
TRANSMISSION OIL FILTER SENSOR
RADIATOR WATER LEVEL SENSOR
STEERING OIL TEMPERATURE SENSOR
BRAKE STROKE SENSOR
PMC SYSTEM (MACHINE EQUIPPED WITH ELECTRONIC GOVERNOR) (OP)
SYSTEM DIAGRAM
ELECTRIC CIRCUIT DIAGRAM
POWER TRAIN MANAGEMENT CONTROLLER (PMC)
MESSAGE DISPLAY (MOM)
SENSOR,SWITCHES
ENGINE SPEED SENSOR
TRANSMISSION SPEED SENSOR
ACCELERATOR SENSOR
SUSPENSION PRESSURE SENSOR
SENSORS,SWITCHES
ENGINE OIL LEVEL SENSOR
BRAKE OIL LEVEL SENSOR
HYDRAULIC OIL LEVEL SENSOR
RETARDER OIL LEVEL SENSOR
AIR CLEANER CLOGGING SENSOR
RETARDER BRAKE WEAR SENSOR
HYDRAULIC FILTER SENSOR
RETARDER OIL FILTER SENSOR
FULL-FLOW FILTER SENSOR
BATTERY ELECTROLYTE LEVEL SENSOR
MAINTENANCE MONITOR SYSTEM
SYSTEM DIAGRAM
MONITOR PANEL
MONITOR DISPLAY,FUNCTIONS
FUNCTIONS OF SWITCHES
SENSORS,SWITCHES
ENGINE OIL LEVEL SENSOR
RADIATOR WATER LEVEL SENSOR
TRANSMISSION OIL LEVEL SENSOR
HYDRAULIC OIL LEVEL SENSOR
RETARDER OIL LEVEL SENSOR
AIR FILTER CLOGGING SENSOR
RETARDER BRAKE WEAR SENSOR
HYDRAULIC FILTER SENSOR
RETARDER OIL FILTER SENSOR
TRANSMISSION OIL FILTER SENSOR
BATTERY ELECTROLYTE LEVEL SENSOR
TORQUE CONVERTER OIL TEMPERATURE SWITCH
RETARDER OIL TEMPERATURE SWITCH
ABS/ASR SYSTEM
SYSTEM CIRCUIT DIAGRAM
PRINCIPLE OF OPERATION
WHEN ABS IS ACTUATED
WHEN ASR IS ACTUATED
SYSTEM STRUCTURE DIAGRAM
ABS/ASR ELECTRICAL CIRCUIT DIAGRAM
ABS/ASR CONTROLLER (ECU)
ABS PRESSURE CONTROL VALVE
ASR CONTROL VALVE
WHEEL SPEED SENSOR
RELAY
ASR-Ⅱ SYSTEM (IF EUQIPPED)
SYSTEM DIAGRAM
BASIC OPERATION
SYSTEM CONFIGURATION
CONTROLLER OF AUTOMATIC SPIN REGULATOR
HYDRAULIC TANK PRESSURIZING SYSTEM (HIGH ALTITUDE SPECIFICATION)
ELECTRICAL CIRCUIT DIAGRAM OF HYDRAULIC TANK PRESSURIZING SYSTEM

20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE BELATED PARTS
STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
TESTING AND ADJUSTING
TOOLS FOR TESTING,ADJUSTING AND TROUBLESHOOTING
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
MEASURING BLOWBY PRESSURE
MEASURING BOOST PRESSURE
MEASURING EXHAUST TRMPERATURE
TESTING AND ADJUSTING FUEL INJECTION TIMING
ADJUSTING ALTERNATOR BELT TENSION
ADJUSTING ENGINE SPEED SENSOR
ADJSUTING TRANSMISSION SPEED SENSOR
ADJUSTING ACCELERATOR PEDAL
TESTING HYDRAULIC PRESSURE OF TORQUE CONVERTER VALVE
TESTING ECMV HYDRAULIC PRESSURE
TESTING TRANSMISSION LUBRICATION PRESSURE
TESTING TORQUE CONVERTER STALL SPEED
TESTING BRAKE PRESSURE
BLEEDING AIR FROM BRAKE CIRCUIT
TESTING WEAR OF FRONT BRAKE PAD
TESTING WEAR OF REAR BRAKE DISC
ADJUSTING PARKING BRAKE
TESTING BRAKE PERFORMANCE
TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER (WITH VARIABLE DAMPING FORCE SELECTOR VALVE)
TESTING AND ADJUSTING INVERTED TYPE REAR SUSPENSION CYLINDER
TESTING AND ADJUSTING SUSPENSION AIR CYLINDER
TESTING AND ADJUSTING AIR PRESSURE IN AIR CIRCUIT
ADJUSTING HOIST LEVER LINKAGE
ADJUSTING BODY POSITIONER
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING,HOIST CIRCUIT
AIR BLEEDING FROM STEERING CYLINDER
ADJUSTING ELECTRONIC MONITOR (SPEEDOMETER,TACHOMETER MODULE)
ADJUSTING Q [FUEL INJECTION AMOUNT] WHEN REPLACING ENGINE CONTROLLER
SETTING ROTARY SWITCH (MODEL DATA,NETWORK DATA) WHEN REPLACING TRANSMISSION CONTROLLER
METHOD OF DELETING DATA FROM ENGINE CONTROLER,TRANSMISSION CONTROLLER AND PMC MEMORY (CONTROL FROM MONITOR PANEL)
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM
PROCEDURE FOR OPERATING MODULATION CHECKER
ADJUSTING HYDRAULIC TANK PRESSURE (HIGH ALTITUDE SPECIFICATION)
PERFORMING PM CLINIC USING MANUAL SNAPSHOT (=QUICK PM)
PM-CLINIC SERVICE
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
TYPE OF CONNECTOR AND POSITION OF INSTALLATION
CONNECTOR PIN ALLOCATION CHART
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
EXPLANATIONS OF FUNCTIONS (CONTROL MECHANISM) OF ELECTRICAL SYSTEM
MONITOR PANEL USER CODES AND SERVICE MODE FUNCTION
SELF-DIAGNOSTIC DISPLAY METHOD FOR MONITOR PANEL AND CONTROLLERS
TABLE OF SERVICE CODES AND USER CODES
METHOD OF USING JUDGEMENT TABLE
METHOD OF USING TROUBLESHOOTING CHARTS
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (ELECTRONIC GOVERNOR SPECIFICATION G MODE)
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE
JUDGMENT TABLE FOR TRANSMISSION CONTROLLER,TRANSMISSION RELATED PARTS
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE CONTROLLER SYSTEM
G-1 C010 [E.<--1.0] ABNORMALITY IN POWER SOURCE
G-2 C011 [E.<--1.1] ABNORMALITY IN CONTROLLER
G-3 C012 [E.<--1.2] ABNORMALITY IN RACK SENSOR SYSTEM
G-4 C013 [E.<--1.3] ABNORMALITY IN RACK SENSOR SYSTEM LEFT BANK
G-5 C014 [E.<--1.4] ABNORMALITY IN GOVERNOR SOLENOID SYSTEM RIGHT BANK
G-6 C015 [E.<--1.5] ABNORMALITY IN GOVERNOR SOLENOID SYSTEM LEFT BANK
G-7 C016 [E.<--1.6] ABNORMALITY IN GOVERNOR CUT RELAY SYSTEM RIGHT BANK
G-8 C017 [E.<--1.7] ABNORMALITY IN GOVERNOR CUT RELAY SYSTEM LEFT BANK
G-9 C018 [E.<--1.8] ABNORMALITY IN RACK SENSOR POWER SOURCE SYSTEM
G-10 C019 [E.<--1.9] ABNORMALITY IN GOVERNOR SERVO SYSTEM RIGHT BANK
G-11 C01A [E.<--1.A] ABNORMALITY IN GOVERNOR SERVO SYSTEM LEFT BANK
G-12 C01b [E.<--1.b] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM A
G-13 C01C [E.<--1.C] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM B
G-14 C01d [E.<--1.d] ABNORMALITY IN PRE-STROKE SOLENOID SYSTEM RIGHT BANK
G-15 C01E [E.<--1.E] ABNORMALITY IN PRE-STROKE SOLENOID SYSTEM LEFT BANK
G-16 C021 [E.<--2.1] MISTAKEN CONNECTION OF CONNECTOR
G-17 C022 [E.<--2.2] ENGINE OVERRUN
G-18 C023 [E.<--2.3] ENGINE OVERHEATING
G-19 C024 [E.<--2.4] DROP IN ENGING OIL PRESSURE
G-20 C031 [E.<--3.1] ABNORMALITY IN ACCELERATION SENSOR SYSTEM
G-21 C034 [E.<--3.4] ABNORMALITY IN ENGINE WATER TEMPERATURE SYSTEM
G-22 C036 [E.<--3.6] ABNORMALITY IN ENGINE OIL PRESSURE SENSOR
G-23 C055 [E.<--5.5] ABNORMALITY IN NETWORK
G-24 C056 [E.<--5.6] ABNORMALITY IN SOLENOID POWER SOURCE SYSTEM RIGHT
G-25 C057 [E.<--5.7] ABNORMALITY IN SOLENOID POWER SOURCE SYSTEM LEFT
G-26 C058 [E.<--5.8] ABNORMALITY IN BACKUP POWER SOURCE SYSTEM
G-27 C059 [E.<--5.9] ABNORMALITY IN BACKUP POWER SOURCE SYSTEM
G-28 C0C2 [E.<--C.2] DEFECTIVE MODEL SELECTION DATA
G-29 C0C4 [E.<--C.4] ABNORMALITY IN ACCELERATION SENSOR SYSTEM
G-30 C0C5 [E.<--C.5] ABNORMALITY IN IDLING VALIDATION
G-31 ENGINE DOES NOT START
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)
METHOD OF USING TROUBLESHOOTING CHART
S-1 STARTING PERFORMANCE IS POOR(STARTING ALWAYS TAKES TIME)
S-2 ENGINE DOES NOT START
a) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)
b) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)
S-3 ENGINE DOES NOT PICK-UP SMOOTHLY(FOLLOW-UP IS POOR)
S-4 ENGINE STOPS DURING OPERATIONS
S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)
S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION)
S-8 OIL CONSUMPTION IS EXCESSIVE(OR EXHAUST SMOKE IS BLUE)
S-9 OIL BECOMES CONTAMINATED QUICKLY
S-10 FUEL CONSUMPTION IS EXCESSIVE
S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP(DROP IN OIL PRESSURE)
S-13 OIL LEVEL RISES
S-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING)
S-15 ABNORMAL NOISE IS MADE
S-16 VIBRATION IS EXCESSIVE
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A MODE)
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER,TRANSMISSION RELATED PARTS
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM
A-1 ABNORMALITY IN POWER SOURCE SYSTEM
a) [v.v][OFF]CONTROLLER SELF-DIAGNOSTIC DISPLAY LED DOES NOT LIGHT UP
b) bOO1 [E. <--0.1,E.C<--0.1] DROP IN VOLTAGE OF CONTROLLER POWER SOURCE IS DISPLAYED
c) bOdA [E. <--d.A,E.C<--d.A] DROP IN VOLTAGE OF BATTERY DIRECT POWER SOURCE IS DISPLAYED
d) bOdb [E. <--d.b,E.C<--d.b] DROP IN VOLTAGE OF MAIL POWER SOURCE IS DISPLAYED
e) bOO2 [E. <--0.2,E.C<--0.2] ABNORMALITAY IN TRANSMISSION CUT RELAY POWER SOURCE IS DISPLAYED
A-2 bOO3 [E. <--0.3,E.C<--0.3] ABNORMALITY IN NEUTRAL SAFETY SYSTEM IS DISPLAYED
A-3 bOO5 [E. <--0.5,E.C<--0.5] DOUBLE ENGAGEMENT FOR CLUTCH IS DISPLAYED
A-4 bOO6 [E. <--0.6,E.C<--0.6] ABNORMALITY IN TRANSMISSION [CUT RELAY] SYSTEM DISPLAYED
A-5 bOO8 [E. <--0.8,E.C<--0.8] ABNORMALITY IN REAR BRAKE SOLENOID SYSTEM IS DISPLAYED
A-6 bOO9 [E. <--0.9,E.C<--0.9] ABNORMALITY IN EXHAUST BRAKE SOLENOID SYSTEM IS DISPLAYED
A-7
a) bOC4 [E. <--C.4,E.C<--C.4] SHORT CIRCUIT WITH GROUND IN BCV REAR SOLENOID IS DISPLAYED
b) bOC6 [E. <--C.6,E.C<--C.6] SHORT CIRCUIT IN BCV REAR SOLENOID IS DISPLAYED
c) bOC8 [E. <--C.8,E.C<--C.8] DISCONNECTION IN BCV REAR SOLENOID IS DISPLAYED
A-8 ABNORMALITY IN SPEED SENSOR SYSTEM
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)
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
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
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
A-9 SPEED SENSOR SYSTEM,CLUTCH SLIPPING
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
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
A-10 ABNORMALITY IN MODEL SELECTION (WIRING HARNESS) IS DISPLAYED
a) b014 [E. <--1.4,E.C<--1.4] ABNORMALITY IN MODEL SELECTION(WIRING HARNESS)IS DISPLAYED
b) b0A1 [E. <--A.1,E.C<--A.1] ABNORMALITY IN MODEL SELECTION(ROTARY SWITCH)IS DISPLAYED
A-11 ABNORMALITY IN SHIFT LEVER SYSTEM
a) b007 [E. <--0.7,E.C<--0.7] SHORT CIRCUIT IN SHIFT LEVER ASSEMBLY POWER SOURCE IS DISPLAYED
b) b015 [E. <--1.5,E.C<--1.5] SHIFT LEVER POSITION SIGNAL INPUT FOR 2 OR MORE SYSTEM IS DISPLAYED
c) b016 [E. <--1.6,E.C<--1.6] SHIFT LEVER POSITION SIGNAL IS NOT INPUT
A-12 b017 [E. <--1.7,E.C<--1.7] ABNORMALITY IN ACCELERATOR SIGNAL IS DISPLAYED
A-13 b019 [E. <--1.9,E.C<--1.9] ABNORMALITY IN TRANSMISSION OIL TRMPERATURE SENSOR IS DISPLAYED
A-14 ABNORMALITY IN PRESSURE CONTROL VALVE SYSTEM
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
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
b-1) INSPECTING FILL SIGNAL SYSTEM
b-2) b042 [E. <--4.2,E.C<--4.2] ・ b043 [E. <--4.3,E.C<--4.3] INSPECTING TRANSMISSION INPUT SHAFT SPEED SIGNAL SYSTEM,H,L CLUTCH SYSTEM(CHECK CLUTCH SLIP)
b-3) b044 [E. <--4.4,E.C<--4.4] ・ b048 [E. <--4.8,E.C<--4.8] INSPECTING TRANSMISSION OUTPUT SHAFT SPEED SIGNAL SYSTEM,1-4,R CLUTCH SYSTEM(INSPECTING CLUTCH SLIP)
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)
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
A-16 b091 [E. <--9.1,E.C<--9.1] - b098 [E. <--9.8,E.C<--9.8] DISCONNECTION IN PRESSURE CONTROL VALVE SOLENOID SYSTEM IS DISPLAYED
A-17 ABNORMALITY IN SENSOR SYSTEM
a) b0A2 [E. <--A.2,E.C<--A.2] ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE SENSOR SYSTEM IS DISPLAYED
b) b0A3 [E. <--A.3,E.C<--A.3] ABNORMALITY IN FUEL LEVEL SENSOR SYSTEM IS DISPLAYED
c) b0b2 [E. <--b.2,E.C<--b.2] ABNORMALITY IN COOLING WATER TEMPERATURE SENSOR SYSTEM IS DISPLAYED
d) b0b3 [E. <--b.3,E.C<--b.3] ABNORMALITY IN AIR PRESSURE SENSOR SYSTEM IS DISPLAYED
e) b0b4 [E. <--b.4,E.C<--b.4] ABNORMALITY IN RETARDER BRAKE OIL TEMPERATURE SENSOR IS DISPLAYED
A-18 WARNING DISPLAY
a) b0d1 [E. <--d.1,E.C<--d.1] TRANSMISSION FILTER CLOGGED WARNING IS DISPLAYED
b) b0d5 [E. <--d.5,E.C<--d.5] TILT WARNING IS DISPLAYED
c) b0d6 [E. <--d.6,E.C<--d.6] DROP IN RADIATOR WATER LEVEL WARNING IS DISPLAYED
d) b0d7 [E. <--d.7,E.C<--d.7] BATTERY CHARGE LEVEL WARNING IS DISPLAYED
e) b0E5 [E. <--E.5,E.C<--E.5] STEERING OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED
f) b0F5 [E. <--F.5,E.C<--F.5] DROP IN ENGINE OIL PRESSURE WARNING IS DISPLAYED (MECHANICAL GOVERNOR SPECIFICATION MACHINE)
g) b0F6 [E. <--F.6,E.C<--F.6] REAR BRAKE OIL PRESSURE WARNING IS DISPLAYED
A-19 b0b7 [E. <--b.7,E.C<--b.7] ABNORMALITY IN ENGINE OIL PRESSURE SYSTEM SENSOR IS DISPLAYED (MECHANICAL GOVERNOR SPECIFITION MACHINE)
A-20 b0C1 [E. <--C.1,E.C<--C.1] ABNORMALITY IN CONNECTOR CONNECTION IS DISPLAYED
A-21
a) b0d2 [E. <--d.2,E.C<--d.2] TORQUE CONVERTER OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED
b) b0d3 [E. <--d.3,E.C<--d.3] ENGINE WATER TEMPERATURE OVERHEAT WARNING IS DISPLAYED
c) b0E9 [E. <--E.9,E.C<--E.9] AIR PRESSURE DROP WARNING IS DISPLAYED
d) b0F3 [E. <--F.3,E.C<--F.3] RETARDER BRAKE OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED
e) b0d8 [E. <--d.8,E.C<--d.8] ENGINE OVERRUN ACTUATED IS DISPLAYED
f) b0d9 [E. <--d.9,E.C<--d.9] ENGINE OVERSHOOT ACTUATED IS DISPLAYED
TROUBLESHOOTING OF SUSPENSION CONTROLLER SYSTEM (SP MODE)
JUDGMENT TABLE FOR SUSPENSION CONTROLLER,SUSPENSION RELATED PARTS
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE
ELECTRICAL CIRCUIT DIAGRAM OF SUSPENSION CONTROLLER SYSTEM
SP-1 d001 [ALL OFF or E.<--01] ABNORMALITY IN POWER SOURCE IS DISPLAYED
SP-2 d011 [E.<--11 IS DISPLAYED] ABNORMALITY IN PRESSURE SENSOR [RIGHT] SYSTEM IS DISPLAYED
SP-3 d012 [E.<--12 IS DISPLAYED] ABNORMALITY IN PRESSURE SENSOR [LEFT] SYSTEM IS DISPLAYED
SP-4 d015 [E.<--15 IS DISPLAYED] ABNORMALITY IN TRAVEL SPEED SENSOR SYSTEM IS DISPLAYED
SP-5 d016 [E.<--16 IS DISPLAYED] ABNORMALITY IN STEERING SENSOR SYSTEM IS DISPLAYED
SP-6 d0C2 [E.<--C2 IS DISPLAYED] DEFECTIVE MODEL SELECTION DATA IS DISPLAYED
SP-7 d021 [E.<--21 IS DISPLAYED] ABNORMALITY IN SOLENOID [1] SYSTEM IS DISPLAYED
SP-8 d022 [E.<--22 IS DISPLAYED] ABNORMALITY IN SOLENOID [2] SYSTEM IS DISPLAYED
SP-9 d023 [E.<--23 IS DISPLAYED] ABNORMALITY IN SOLENOID [3] SYSTEM IS DISPLAYED
SP-10 d0C1 [E.<--C1 IS DISPLAYED] DISCONNECTION IN NETWROK IS DISPLAYED
SP-11 d0C3 [E.<--C3 IS DISPLAYED] DEFECTIVE TRAVEL SPEED COMPENSATION DATA IS DISPLAYED
TROUBLESHOOTING OF PAYLOAD METER (PRINTER TYPE) SYSTEM (LP MODE)
SERVICE CODES AND SELF-DIAGNOSIS OF PAYLOAD METER (PRINTER TYPE)
ELECTRIC CIRCUIT DIAGRAM FOR PAYLOAD METER (PRINTER TYPE) SYSTEM
LP-1 NO DISPLAY APPEARS WHEN STARTING SWITCH IS TURNED ON
LP-2 CALIBRATION DEMAND (CAL FLASHES) IS SHOWN CONTINUOUSLY AFTER STARTING SWITCH IS TURNED ON
LP-3 CALIBRATION CANNOT BE CARRIED OUT
LP-4 AFTER STARTING SWITCH IS TURNED ON,ALL EXTERNAL DISPLAY LAMPS DO NOT LIGHT UP
LP-5 CONDITION DOES NOT EXIST FOR LAMPS TO LIGHT UP,BUT EXERNAL DISPLAY LAMPS LIGHT UP
LP-6 LEVEL OF LIGHTING UP OF EXTERNAL DISPLAY LAMPS IS NOT CORRECT
LP-7 ABNORMALITY IN DISPLAY LOGIC
LP-8 E01-E04 IS DISPLAYED
LP-9 E11-E14 IS DISPLAYED
LP-10 E21-E28 IS DISPLAYED BY SENSOR CHECK
LP-11 E31 IS DISPLAYED
LP-12 E32 IS DISPLAYED
LP-13 E41 IS DISPLAYED
LP-14 E42 IS DISPLAYED
LP-15 PRINTER DOES NOT PRINT ANYTHING (BLANK PAPER COMES OUT)
LP-16 PRINTER PRINTS ONLY "NO DATA"
LP-17 PRINTER DOES NOT PRINT OUT WHEN PRT SWITCH IS PRESSED
LP-18 "PAPE" FLASHES
LP-19 TIME IS WRONG
LP-20 E33 IS DISPLAYED
TROUBLESHOOTING OF PAYLOAD METER Ⅱ (CARD TYPE) SYSTEM (LC MODE)
SERVICE CODES AND SELF-DIAGNOSIS OF PAYLOAD METER Ⅱ (CARD TYPE)
ELECTRICAL CIRCUIT DIAGRAM FOR PAYLOAD METER Ⅱ (CARD TYPE) SYSTEM
LC-1 NO DISPLAY APPEARS WHEN STARTING SWITCH IS TURNED ON
LC-2 AFTER STARTING SWITCH IS TURNED ON,ALL EXTERNAL DISPLAY LAMPS DO NOT LIGHT UP
LC-3 CONDITION DOES NOT EXIST FOR LAMPS TO LIGHT UP,BUT EXTERNAL DISPLAY LAMPS LIGHT UP
LC-4 LEVEL OF LIGHTING UP OF EXTERNAL DISPLAY LAMPS IS NOT CORRECT
LC-5 CYCLE DATA IS NOT RECOREDE,ON/OFF DATA IS NOT RECORDED:BATTERY CHARGE SIGNAL SYSTEM:ENGINE IS NOT STARTED IS DETECTED
LC-6 CALIBRATION CANNOT BE CARRIED OUT,TIME DISPLAY DOES NOT MATCH CONDITIONS:SHIFT LEVER N POSITION SIGNAL SYSTEM
LC-7 ABNORMALITY IN DISPLAY LOGIC
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
LC-9 F-09 IS DISPLAYED:DROP IN VOLTAGE OF BACK-UP BATTERY BUILT INTO PAYLOAD METER
LC-10 FULL DISPLAY APPEARS
LC-11 F-20 IS DISPLAYED:SENSOR POWER SOURCE VOLTAGE SYSTEM
LC-12 F-21 - F-24 IS DISPLAYED:DISCONNECTION,SHORT CIRCUIT WITH GROUND SUSPENSION PRESSURE SENSOR SYSTEM
LC-13 F-25 - F-28 IS DISPLAYED:SHORT CIRCUIT IN SUSPENSION PRESSURE SENSOR SYSTEM POWER SOURCE
LC-14 F.CAL IS DISPLAYED:CALIBRATION NOT CARRIED OUT,DAMAGED DATA INSIDE PAYLOAD METER
LC-15 F-41 - F-45 IS DISPLAYED:SHORT CIRCUIT IN EXTERNAL DISPLAY LAMP SYSTEM POWER SOURCE
LC-16 L-BAD IS DISPLAYED:CYCLE DATA SAVED WHEN MACHINE WAS SWAYING
LC-17 MACHINE IS NOT LOADING BUT EXTERNAL DISPLAY LAMPS GIVE LOAD ESTIMATE DISPLAY. AFTER LOADING,DISPLAY SWITCHES TO TIME DISPLAY BEFORE TRAVELING 160m
LC-18 F-31 IS DISPLAYED:DISCONNECTION,SHORT CIRCUIT WITH GROUND IN CLINOMETER SYSTEM
LC-19 F-32 IS DISPLAYED:SHORT CIRCUIT WITH CLINOMETER SYSTEM POWER SOURCE
LC-20 F-18 IS DISPLAYED:DISCONNECTION IN BATTERY CHARGE SIGNAL
LC-21 F-93 - 99 ARE DISPLAYED:ABNORMALITY IN NETWORK (WHEN PMC IS INSTALLED)
LC-22 F-71,73,80,91,92 ARE DISPLAYED:(WHEN PMC,TALKS ARE INSTALLED)
TROUBLESHOOTING OF ARSC [AUTOMATIC RETARDER SPEED CONTROLLER] SYSTEM (R MODE)
OUTLINE
ELECTRICAL CIRCUIT DIAGRAM FOR ARSC (AUTOMATIC RETARDER SPEED CONTROLLER) SYSTEM
R-1 0.1 (ABNORMALITY IN POWER SOURCE VOLTAGE) IS DISPLAYED
R-2 1.0 (DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED
R-3 1.3 (DISCONNECTION IN TRANSMISSION OUTPUT SHAFT SPEED SENSOR SYSTEM) IS DISPLAYED
R-4 1.5 (FAILURE IN RETARDER OIL TEMPERATURE SENSOR SYSTEM) IS DISPLAYED
R-5 1.7 (FAILURE IN ACCELERATOR SIGNAL SYSTEM) IS DISPLAYED
R-6 1.8 (FAILURE IN SUSPENSION PRESSURE SENSOR "LEFT" SYSTEM) IS DISPLAYED
R-7 1.9 (FAILURE IN SUSPENSION PRESSURE SENSOR "RIGHT" SYSTEM) IS DISPLAYED
R-8 4.2 (DISCONNECTION IN EXHAUST BRAKE SELECTOR SIGNAL SYSTEM) IS DISPLAYED
R-9 4.3 (DISCONNECTION IN ARSC CAUTION LAMP SYSTEM) IS DISPLAYED
R-10 4.4 (DISCONNECTION IN READY LAMP SYSTEM) IS DISPLAYED
R-11 4.5 (DISCONNECTION IN PANEL CAUTION AND BUZZER SYSTEM) IS DISPLAYED
R-12 5.2 (SHORT CIRCUIT WITH GROUND EXHAUST BRAKE SELECTOR SIGNAL OUTPUT SYSTEM) IS DISPLAYED
R-13 5.3 (SHORT CIRCUIT WITH GROUND IN ARSC CAUTION LAMP SYSTEM) IS DISPLAYED
R-14 5.4 (SHORT CIRCUIT WITH GROUND IN READY OUTPUT CIRCUIT SYSTEM) IS DISPLAYED
R-15 5.5 (SHORT CIRCUIT WITH GROUND IN PANEL CAUTION LAMP AND BUZZER OUTPUT SYSTEM) IS DISPLAYED
R-16 6.0 (FAILURE IN ENGINE SPEED SYSTEM) IS DISPLAYED
R-17 7.0 (DISCONNECTION IN TRAVEL SPEED DISPLAY UP OUTPUT SYSTEM) IS DISPLAYED
R-18 7.1 (DISCONNECTION IN TRAVEL SPEED DISPLAY DOWN OUTPUT SYSTEM) IS DISPLAYED
R-19 7.2 (DISCONNECTION IN TRAVEL SPEED DISPLAY CLEAR OUTPUT SYSTEM) IS DISPLAYED
R-20 7.3 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY UP OUTPUT SYSTEM) IS DISPLAYED
R-21 7.4 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY DOWN OUTPUT SYSTEM) IS DISPLAYED
R-22 7.5 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY CLEAR OUTPUT SYSTEM) IS DISPLAYED
R-23 8.1 (SHORT CIRCUIT WITH GROUND IN PRESSURE CONTROL VALVE SYSTEM) IS DISPLAYED
R-24 8.3 (DISCONNECTION IN PRESSURE CONTROL VALVE SYSTEM) IS DISPLAYED
R-25 8.5 (FAILURE IN PRESSURE CONTROL VALVE (PRESSURE CONTROL VALVE REMAINS OPEN)) IS DISPLAYED
R-26 8.7 (FAILURE IN PRESSURE CONTROL VALVE (PRESSURE CONTROL VALVE DOES NOT OPEN)) IS DISPLAYED
R-27 8.9 (SHORT CIRCUIT WITH GROUND IN PRESSURE SWITCH VALVE SYSTEM) IS DISPLAYED
R-28 9.0 (DISCONNECTION IN PRESSURE SWITCH VALVE SYSTEM) IS DISPLAYED
R-29 9.1 (FAILURE IN PRESSURE SWITCH VALVE SYSTEM (REMAINS OPEN)) IS DISPLAYED
R-30 9.2 (FAILURE IN PRESSURE SWITCH VALVE SYSTEM (DOES NOT OPEN)) IS DISPLAYED
R-31 9.3 (DISCONNECTION IN SYSTEM SWITCH SYSTEM) IS DISPLAYED
R-32 9.4 (SHORT CIRCUIT WITH GROUND IN SYSTEM SWITCH SYSTEM0 IS DISPLAYED
R-33 9.5 (DISCONNECTION,SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED SETTING SWITCH SYSTEM) IS DISPLAYED
R-101 SET SPEED CANNOT BE SET
R-102 FAILURE CODE IS ALWAYS CLEARED (CONTROLLER DISPLAY WINDOW ALWAYS SHOWS "--") OR FAILURE CODE CANNOT BE CLEARED
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)
R-104 ABNORMALITY APPEARS IN OTHER CONTROLLER
R-105 WHEN TRAVELING DOWNHILL,EVEN WHEN SET SPEED IS EXCEEDED,NO CONTROL IS CARRIED OUT
R-106 MONITOR LAMP (BUZZER) STAYS ON (OR OFF)
R-107 READY LAMP DOES NOT LIGHT UP (OR STAYS LIGHTED UP)
R-108 EXHAUST BRAKE DOES NOT WORK PROPERLY
R-108 [EXHAUST BRAKE IS ACTUATED WHEN EXHAUST BRAKE SWITCH IS OFF;OR EXHAUST BRAKE IS NOT ACTUATED WHEN EXHAUST BRAKE SWITCH IS ON]
R-109 THERE IS DIFFERENCE BETWEEN TRAVEL SPEED ROD VALUE AND ACTUAL MACHINE VALUE
R-110 RETARDER LAMP DOES NOT LIGHT UP,OR STAYS LIGHTED UP
R-111 TRAVEL SPEED DISPLAY ALWAYS GIVES DISPLAY (OR DOES NOT GIVE ANY DISPLAY)
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)
H-1 MACHINE DOES NOT START
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY
H-3 LOCK-UP CLUTCH CANNOT BE DISENGAGED
H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING
H-5 TRANSMISSION DOES NOT SHIFT UP
H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING
H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR
H-8 TORQUE CONVERTER OIL TEMPERATURE IS LIGH
H-9 TORQUE CONVERTER OIL PRESSURE IS LOW
H-10 FRONT BRAKE IS INEFFECTIVE,OR EFFECTIVE ONLY ON ONE SIDE
H-11 REAR BRAKE IS INEFFECTIVE,OR EFFECTIVE ONLY ON ONE SIDE
H-12 STEERING WHEEL IS HEAVY
H-13 STEERING WHEEL DOES NOT WORK
H-14 STEERING WHEEL VIBRATES
H-15 HOIST CYLINDER LACKS LIFTING FORCE (LIFTING SPEED)
H-16 HOIST CYLINDER DOES NOT WORK
H-17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY
H-18 AIR PRESSURE DOES NOT RISE
TROUBLESHOOTING OF MONITOR PANEL SYSTEM (P MODE)
METHOD OF SELF-DIAGNOSTIC DISPLAY FOR MONITOR PANEL AND CONTROLLERS
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE (MONITOR PANEL SYSTEM)
ELECTRICAL CIRCUIT DIAGRAM FOR MONITOR PANEL SYSTEM
P-1 CHECK PATTERN FOR WIRING HARNESSES BETWEEN MODULES
P-2 NOTHING ON MONITOR PANEL WORKS
P-3 LH,RH MODULE AND FUEL GAUGE DO NOT WORK
P-4 LH,RH MODULE AND FUEL GAUGE DO NOT WORK
P-5 RH MODULE DOES NOT WORK
P-6 LH MODULE DOES NOT WORK
P-7 TRAVEL CALCULATOR DOES NOT WORK
P-8 SERVICE METER DISPLAY DOES NOT WORK CORRECTLY
P-9 CENTRAL WARNING LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS FAILURE CODE (MONITOR PANEL DISPLAY)[A002]
P-10 CENTRAL WARNING LAMP STAYS LIGHTED UP
P-11 ALARM BUZZER DOES NOT WORK,OR MONITOR PANEL DETECTS FAILURE CODE [A003]
P-12 ALARM BUZZER CONTINUES TO SOUND
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]
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]
P-15 GAUGE DISPLAYS ARE ABNORMAL (NOTHING IS DISPLAYED,OR DISPLAY DOES NOT CHANGE)
P-16 COOLING WATER LEVEL DROP CAUTION LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001]
P-17 COOLING WATER LEVEL DROP CAUTION LAMP STAYS LIGHTED UP
P-18 EMERGENCY STEERING PILOT LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SEVICE CODE [A001]
P-19 EMERGENCY STEERING PILOT LAMP STAYS LIGHTED UP
P-20 ENGINE OIL PRESSURE DROP CAUTION LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001]
P-21 ENGINE OIL PRESSURE DROP CAUTION LAMP STAYS LIGHTED UP
P-22 EXHAUST BRAKE PILOT LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001]
P-23 EXHAUST BRAKE PILOT LAMP STAYS LIGHTED UP
P-24 CHARGING CIRCUIT ABNORMALITY CAUTION LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001]
P-25 CHARGING CIRCUIT ABNORMALITY CAUTION LAMP STAYS LIGHTED UP
P-26 TRANSMISSION FILTER CLOGGING CAUTION LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001]
P-27 TRANSMISSION FILTER CLOGGING CAUTION LAMP STAYS LIGHTED UP
P-28 BRAKE STROKE CAUTION LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001]
P-29 BRAKE STROKE CAUTION LAMP STAYS LIGHTED UP
P-30 PREHEATING SWITCH PILOT LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001]
P-31 PREHEATING SWITCH PILOT LAMP STAYS LIGHTED UP
P-32 TILT WARNING LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001]
P-33 TILT WARNING LAMP STAYS LIGHTED UP
P-34 BODY FLOAT (EXCEPT FLOAT) PILOT LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001]
P-35 BODY FLOAT (EXCEPT FLOAT) PILOT LAMP STAYS LIGHTED UP
P-36 REAR BRAKE PILOT LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001]
P-37 REAR BRAKE PILOT LAMP STAYS LIGHTED UP
P-38 PARKING BRAKE PILOT LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001]
P-39 PARKING BRAKE PILOT LAMP STAYS LIGHTED UP
P-40 MAINTENANCE CAUTION LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001]
P-41 MAINTENANCE CAUTION LAMP STAYS LIGHTED UP
P-42 STEERING OIL TEMPERATURE CAUTION LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001]
P-43 STEERING OIL TEMPERATURE CAUTION LAMP STAYS LIGHTED UP
P-44 DIFFERENTIAL LOCK PILOT LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001]
P-45 DIFFERENTIAL LOCK PILOT LAMP STAYS LIGHTED UP
P-46 HIGH BEAM DISPLAY DOES NOT LIGHT UP
P-47 TURN SIGNAL LAMP (RIGHT) DOES NOT LIGHT UP
P-48 TURN SIGNAL LAMP (LEFT) DOES NOT LIGHT UP
P-49 LAMP CHECK SWITCH DOES NOT WORK
P-50 AISS SWITCH DOES NOT WORK
P-51 EXHAUST BRAKE SWITCH DOES NOT WORK
P-52 MODE CHANGE SWITCH (1) DOES NOT WORK
P-53 MODE CHANGE SWITCH (2) DOES NOT WORK
P-54 KPH/MPH SPEEDOMETER UNIT SELECTOR DOES NOT WORK
P-55 DEFECTIVE OPERATION OF ALL SWITCH INPUTS
P-56 MONITOR PANEL DETECTS SERVICE CODES [A014] OR [A019]
P-57 MONITOR PANEL DETECTS SERVICE CODE [A015]
P-58 MONITOR PANEL DETECTS SERVICE CODE [A011]
P-59 MONITOR PANEL DETECTS SERVICE CODE [A012]
P-60 MONITOR PANEL DETECTS SERVICE CODE [A000]
TROUBLESHOOTING OF PMC SYSTEM (M MODE)
PMC RELATED ELECTRIC CIRCUIT DIAGRAM
M-1 PMC DOES NOT WORK
M-2 E001 [0.1:FLASHES] FAILURE IN NV RAM DATA IS DISPLAYED
M-3 E002 [0.2:FLASHES] DROP IN BATTERY DIRECT POWER SOURCE VOLTAGE IS DISPLAYED
M-4 E003 [0.3:FLASHES] ABNROMALITY IN CONNECTOR CONNECTION IS DISPLAYED
M-5 E011 [1.1:FLASHES] DISCONNECTION IN GSP COMMUNICATIONS IS DISPLAYED
M-5 E012 [1.2:FLASHES] ABNORMALITY IN GSP COMMUNICATIONS IS DISPLAYED
M-6 E013 [1.3:FLASHES] DISCONNECTION IN MOM COMMUNICATIONS IS DISPLAYED
M-6 E014 [1.4:FLASHES] ABNORMALITY IN MOM COMMUNICATIONS IS DISPLAYED
M-7 E015 [1.5:FLASHES] DISCONNECTION IN TMS COMMUNICATIONS IS DISPLAYED
M-7 E016 [1.6:FLASHES] ABNORMALITY IN TMS COMMUNICATIONS IS DISPLAYED
M-8 E017 [1.7:FLASHES] DISCONNECTION IN CENSE COMMUNICATIONS IS DISPLAYED
M-8 E018 [1.8:FLASHES] ABNORMALITY IN CENSE COMMUNICATIONS IS DISPLAYED
M-9 E026 [2.6:FLASHES] COMMUNICATIONS ABNORMALITY 1 IS DISPLAYED
M-9 E027 [2.7:FLASHES] COMMUNICATIONS ABNORMALITY 2 IS DISPLAYED
M-9 E028 [2.8:FLASHES] COMMUNICATIONS ABNORMALITY 3 IS DISPLAYED
M-9 E029 [2.9:FLASHES] COMMUNICATIONS ABNORMALITY 4 IS DISPLAYED
M-9 E02A [2.A:FLASHES] COMMUNICATIONS ABNORMALITY 5 IS DISPLAYED
M-10 E035 [3.5:FLASHES] ABNORMALITY IN IDLING VALIDATION IS DISPLAYED
M-11 E041 [4.1:FLASHES] SHORT CIRCUIT WITH GROUND/DISCONNECTION IN SUSPENSION PRESSURE SENSOR (RIGHT) SYSTEM IS DISPLAYED
M-11 E042 [4.2:FLASHES] SHORT CIRCUIT WITH GROUND/DISCONNECTION IN SUSPENSION PRESSURE SENSOR (LEFT) SYSTEM IS DISPLAYED
M-11 E043 [4.3:FLASHES] SHORT CIRCUIT IN SUSPENSION PRESSURE SENSOR (RIGHT) SYSTEM IS DISPLAYED
M-11 E044 [4.4:FLASHES] SHORT CIRCUIT IN SUSPENSION PRESSURE SENSOR (LEFT) SYSTEM IS DISPLAYED
M-12 E054 [5.4:FLASHES] DISCONNECTION IN ACCELERATOR SIGNAL SYSTEM IS DISPLAYED
M-13 E055 [5.5:FLASHES] SHORT CIRCUIT IN ACCELERATOR CELL SIGNAL SYSTEM IS DISPLAYED
M-14 E056 [5.6:FLASHES] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED
M-15 E057 [5.7:FLASHES] ABNORMALITY IN INPUT SHAFT SPEED SENSOR SYSTEM IS DISPLAYED
M-16 E058 [5.8:FLASHES] ABNORMALITY IN TRAVEL SPEED SENSOR (TRANSMISSION OUTPUT SHAFT SPEED SENSOR) IS DISPLAYED
M-17 E0A1 [A.1:FLASHES] WHEN ENGINE IS NOT RUNNING,DROP IN BRAKE OIL LEVEL IS DISPLAYED
M-18 E0A2 [A.2:FLASHES] WHEN ENGINE IS NOT RUNNING,DROP IN RETARDER OIL LEVEL IS DISPLAYED
M-19 E0A3 [A.3:FLASHES] WHEN ENGINE IS NOT RUNNING,DROP IN HYDRAULIC OIL LEVEL IS DISPLAYED
M-20 E0A6 [A.6:FLASHES] WHEN ENGINE IS RUNNING,RETARDER FILTER CLOGGED IS DISPLAYED
M-21 E0A7 [A.7:FLASHES] WHEN ENGINE IS RUNNING,FULL-FLOW FILTER CLOGGED IS DISPLAYED
M-22 E0A8 [A.8:FLASHES] WHEN ENGINE IS RUNNING,HYDRAULIC FILTER CLOGGED IS DISPLAYED
M-23 E0b2 [b.2:FLASHES] AT NEUTRAL,RIHGT RETARDER BRAKE DISC WEAR IS DISPLAYED
M-24 E0b3 [b.3:FLASHES] AT NEUTRAL,LEFT RETARDER BRAKE DISC WEAR IS DISPLAYED
M-25 E0b4 [b.4:FLASHES] WHEN ENGINE IS NOT RUNNING,DROP IN BATTERY ELECTROLYTE LEVEL IS DISPLAYED
M-26 E0b5 [b.5:FLASHES] WHEN ENGINE IS NOT RUNNING,DROP IN ENGINE OIL LEVEL IS DISPLAYED
M-27 E0b6 [b.6:FLASHES] WHEN ENGINE IS RUNNING,AIR CLEANER CLOGGED IS DISPLAYED
M-28 E0C1 [C.1:FLASHES] ABNORMALITY IN NETWORK SYSTEM IS DISPLAYED
M-28 E0C2 [C.2:FLASHES] ABNORMALITY IN MODEL SELECTION DATA IS DISPLAYED
M-29 E0C3 [C.3:FLASHES] ABNORMALITY IN TRAVEL SPEED COMPENSATION DATA IS DISPLAYED
M-30 SETTING OF PMC DIPSWITCHES
M-101 MOM DISPLAY IS NOT GIVEN
M-102 MOM DISPLAY IS GOES UT
M-103 4-DIGIT ERROR CODE AND ERROR MESSAGE ARE DISPLAYED ON MOM
M-104 MOM TIME DISPLAY IS SLOW,WARNING DISPLAY SHOWS DEFECTIVE OPERATION OF CLOCK IC,OR WARNING DISPLAY SHOWS DROP IN BATTERY VOLTAGE
M-105 (DROP IN BATTERY VOLTAGE) WARNING IS DISPLAYED
TROUBLESHOOTING OF ABS/ASR SYSTEM (OP)
TROUBLESHOOTING FLOWCHART
FOR MACHINES WITH ABS INSTALLED INDEPENDENTLY
FOR MACHINES WITH ABS/ASR INSTALLED
METHOD OF DELETING ECU TROUBLE DATA FROM MEMORY
PROCEDURE FOR DELETING TROUBLE DATA FROM MEMORY
METHOD OF TROUBLESHOOTING USING SELF-DIAGNOSTIC FUNCTION OF ECU
INDEX (TROUBLESHOOTING CODE)
SYSTEM CHECK SHEET FOR USING SYSTEM CHECKER
W-1 WARNING LAMP DOES NOT LIGHT UP
I-1 ASR INFORMATION SWITCH DOES NOT GO OUT
ASR-1 FAILURE IN ASR CONTROL VALVE (ONLY MACHINES WITH ABS/ASR INSTALLED)
ASR-2
ABS-1 FAILURE INSIDE ECU
ABS-2 FAILURE IN FRONT RIGHT PRESSURE CONTROL VALVE
ABS-3 FAILURE IN FRONT LEFT PRESSURE CONTROL VALVE
ABS-4 FAILURE IN REAR LEFT PRESSURE CONTROL VALVE
ABS-5 FAILURE IN REAR RIGHT PRESSURE CONTROL VALVE
ABS-6 FAILURE IN FRONT RIGHT WHEEL SPEED SENSOR
ABS-10 ABNORMALITY IN FRONT RIGHT WHEEL SPEED SENSOR OUTPUT
ABS-7 FAILURE IN FRONT LEFT WHEEL SPEED SENSOR
ABS-11 ABNORMALITY IN FRONT LEFT WHEEL SPEED SENSOR OUTPUT
ABS-8 FAILURE IN REAR WHEEL SPEED SENSOR
ABS-12 ABNORMALITY IN REAR LEFT WHEEL SPEED SENSOR OUTPUT
ABS-9 FAILURE IN REAR RIGHT WHEEL SPEED SENSOR
ABS-13 ABNORMALITY IN REAR RIGHT WHEEL SPEED SENSOR OUTPUT
ABS-14 FAILURE IN VALVE RELAY (VR2)
ABS-15 FAILURE IN VALVE RELAY (VR1)
ABS-16 FAILURE IN VALVE RELAY (VR2)
ABS-17 FAILURE IN VALVE RELAY (VR1)
ABS-18 ABNORMALITY IN POWER SOURCE VOLTAGE
TROUBLESHOOTING FOR MAINTENANCE MONITOR SYSTEM
MM-1 MAINTENANCE MONITOR DOES NOT WORK
a) WHEN NOTHING WORKS
b) WHEN CHECK DISPLAY DOES NOT WORK
MM-2 WHEN ENGINE IS STOPPED,ENGINE OIL LEVEL DISPLAY FLASHES
MM-3 WHEN ENGINE IS STOPPED,TRANSMISSION OIL LEVEL DISPLAY FLASHES
MM-4 WHEN ENGINE IS STOPPED,HYDRAULIC OIL LEVEL DISPLAY FLASHES
MM-5 WHEN ENGINE IS STOPPED,RETARDER OIL LEVEL DISPLAY FLASHES
MM-6 WHEN ENGINE IS STOPPED,BRAKE OIL LEVEL DISPLAY FLASHES
MM-7 WHEN ENGINE IS STOPPED,BATTERY ELECTROLYTE LEVEL DISPLAY FLASHES
MM-8 AT NEUTRAL,RETARDER WEAR DISPLAY FLASHES
MM-9 WHEN ENGINE IS RUNNING,AIR CLEANER CLOGGING DISPLAY FLASHES
MM-10 WHEN ENGINE IS RUNNING,FULL-FLOW FILTER CLOGGING DISPLAY FLASHES
MM-11 WHEN ENGINE IS RUNNING,TRANSMISSION FILTER CLOGGING DISPLAY FLASHES
MM-12 WHEN ENGINE IS RUNNING,HYDRAULIC FILTER CLOGGING DISPLAY FLASHES
MM-13 WHEN ENGINE IS RUNNING,RETARDER FILTER CLOGGING DISPLAY FLASHES
MM-14 MAINTENANCE TIMER DOES NOT WORK
MM-15 MAINTENANCE TIMER IS NOT 0H OR BELOW,BUT MAINTENANCE ITEM LIGHTS UP
MM-16 ABNROMALITY IN SWITCH
a) CONFIRMATION SWITCH FOR OIL OR FILTER REPLACEMENT TIME DOES NOT WORK
b) REPLACEMENT SWITCH,MISOPERATION CANCEL SWITCH DO NOT WORK
MM-17 NIGHT LIGHTING DOES NOT LIGHT UP
TROUBLESHOOTING FOR AUTOMATIC SPIN REGULATOR (ASR-Ⅱ) SYSTEM (AS MODE)
OUTLINE
AS-1 FAILURE CODE 0.1 "ABNORMALITY IN POWER SOURCE VOLTAGE" IS DISPLAYED
AS-2 FAILURE CODE 1.0 "DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM" IS DISPLAYED
AS-3 FAILURE CODE 1.1 "DISCONNECTION IN RR WHEEL SPEED SENSOR" IS DISPLAYED
AS-4 FAILURE CODE 1.2 "DISCONNECTION IN RL WHEEL SPEED SENSOR" IS DISPLAYED
AS-5 FAILURE CODE 1.3 "DISCONNECTION IN TRANSMISSION OUTPUT SHAFT SPEED SENSOR SYSTEM" IS DISPLAYED
AS-6 FAILURE CODE 1.6 "FAILURE IN STEERING ANGLE SENSOR" IS DISPLAYED
AS-7 FAILURE CODE 1.7 "FAILURE IN ACCELERATOR SIGNAL SYSTEM" IS DISPLAYED
AS-8 FAILURE CODE 4.3 "DISCONNECTION IN ARSC CAUTION LAMP SYSTEM" IS DISPLAYED
AS-9 FAILURE CODE 4.5 "DISCONNECTION IN PANEL CAUTION LAMP AND BUZZER SYSTEM" IS DISPLAYED
AS-10 FAILURE CODE 5.3 "SHORT CIRCUIT WITH GROUND IN ARSC CAUTION LAMP SYSTEM" IS DISPLAYED
AS-11 FAILURE CODE 5.5 "SHORT CIRCUIT WITH GROUND IN PANEL CAUTION LAMP AND BUZZER SYSTEM" IS DISPLAYED
AS-12 FAILURE CODE 6.0 "FAILURE IN ENGINE SPEED SENSOR SYSTEM" IS DISPLAYED
AS-13 FAILURE CODE 6.1 "FAILURE IN RR WHEEL SPEED SENSOR SYSTEM" IS DISPLAYED
AS-14 FAILURE CODE 6.2 "FAILURE IN RL WHEEL SPEED SENSOR SYSTEM" IS DISPLAYED
AS-15 FAILURE CODE 8.0 "FAILURE IN PRESSURE CONTROL VALVE (L.H.) SYSTEM:PRESSURE CONTROL VALVE (L.H.)DOES NOT OPEN" IS DISPLAYED
AS-16 FAILURE CODE 8.1 "SHORT CIRCUIT WITH CHASSIS GROUND IN PRESSURE CONTROL VALVE (R.H.) SYSTEM" IS DISPLAYED
AS-17 FAILURE CODE 8.2 "SHORT CIRCUIT WITH CHASSIS GROUND IN PRESSURE CONTROL VALVE (L.H.) SYSTEM" IS DISPLAYED
AS-18 FAILURE CODE 8.3 "DISCONNECTION IN PRESSURE CONTROL VALVE (R.H.) SYSTEM" IS DISPLAYED
AS-19 FAILURE CODE 8.4 "DISCONNECTION IN PRESSURE CONTROL VALVE (L.H.) SYSTEM" IS DISPLAYED
AS-20 FAILURE CODE 8.5 "FAILURE IN PRESSURE CONTROL VALVE (R.H.) SYSTEM:PRESSURE CONTROL VALVE (R.H.) DOES NOT CLOSE" IS DISPLAYED
AS-21 FAILURE CODE 8.6 "FAILURE IN PRESSURE CONTROL VALVE (L.H.) SYSTEM:PRESSURE CONTROL VALVE (L.H.) DOES NOT CLOSE" IS DISPLAYED
AS-22 FAILURE CODE 8.7 "FAILURE IN PRESSURE CONTROL VALVE (R.H.) SYSTEM:PRESSURE CONTROL VALVE (R.H.) DOES NOT OPEN" IS DISPLAYED
AS-23 FAILURE CODE 8.9 "SHORT CIRCUIT WITH CHASSIS GROUND IN PRESSURE SWITCH VALVE SYSTEM" IS DISPLAYED
AS-24 FAILURE CODE 9.0 "DISCONNECTION IN PRESSURE SWITCH VALVE SYSTEM" IS DISPLAYED
AS-25 FAILURE CODE 9.1 "FAILURE IN PRESSURE SWITCH VALVE SYSTEM:VALVE DOES NOT CLOSE" IS DISPLAYED
AS-26 FAILURE CODE 9.2 "FAILURE IN PRESSURE SWITCH VALVE SYSTEM:VALVE DOES NOT OPEN" IS DISPLAYED
AS-101 NOTHING IS DISPLAYED ON DISPLAY WINDOW OF CONTROLLER
AS-102 FAILURE CODE IS KEPT CLEARED ("-" IS ALWAYS DISPLAYED IN DISPLAY WINDOW OF CONTROLLER) OR CANNOT BE CLEARED
AS-103 ANOTHER CONTROLLER HAS A FAILURE
AS-104 MONITOR LAMP (BUZZER) STAYS ON (OR OFF)
AS-105 DISCONNECTION IN SWITCH SYSTEM OF ASR SYSTEM
AS-106 SHORT CIRCUIT WITH CHASSIS GROUND IN SWITCH SYSTEM OF ASR SYSTEM
AS-107 ASR WORKING LAMP DOES NOT LIGHT UP
AS-108 ASR WORKING LAMP REMAINS LIT

30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECAUTIONS WHEN CARRYING OUT OPERATION
SPECIAL TOOL LIST
STARTING MOTOR
REMOVAL AND INSTALLATION
ALTERNATOR
REMOVAL AND INSTALLATION
ENGINE OIL COOLER
REMOVAL AND INSTALLATION
LEFT BANK FUEL INJECTION PUMP
REMOVAL AND INSTALLATION
RIGHT BANK FUEL INJECTION PUMP (WITHOUT GOVERNOR)
REMOVAL AND INSTALLATION
AIR COMPRESSOR
REMOVAL AND INSTALLATION
WATER PUMP
REMOVAL AND INSTALLATION
AFTERCOOLER CORE
REMOVAL
INSTALLATION
TURBOCHARGER
REMOVAL AND INSTALLATION
NOZZLE HOLDER
REMOVAL AND INSTALLATION
CYLINDER HEAD
REMOVAL
INSTALLATION
EXHAUST BRAKE
REMOVAL AND INSTALLATION
ENGINE ASSEMBLY
REMOVAL
INSTALLATION
ENGINE FRONT SEAL
REMOVAL AND INSTALLATION
ENGINE REAR SEAL
REMOVAL AND INSTALLATION
RADIATOR,TORQUE CONVERTER COOLER
REMOVAL
INSTALLTION
BRAKE COOLER
REMOVAL AND INSTALLATION
OUTPUT SHAFT
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
TORQUE CONVERTER,TRANSMISSION
REMOVAL
INSTALLATION
PROCEDURE FOR CENTERING THE ENGINE ASSEMBLY AND TROQUE CONVERTER,TRANSMISSION ASSEMBLY
TORQUE CONVERTER,CONTROL VALVE
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
TORQUE CONVERTER AND TRANSMISSION
DISCONNECTION
CONNECTION
TORQUE CONVERTER,PTO
DISASSEMBLY
ASSEMBLY
TRANSMISSION
DISASSEMBLY
ASSEMBLY
ECMV
DISASSEMBLY AND ASSEMBLY
DIFFERENTIAL (FOR STANDARD DIFFERENTIAL)
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
DIFFERENTIAL (WITH DIFFERENTIAL LOCK)
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
FRONT WHEEL
REMOVAL AND INSTALLATION
REAR WHEEL
REMOVAL
INSTALLATION
FRONT BRAKE CALIPER
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
FRONT BRAKE CALIPER PAD
REMOVAL AND INSTALLATION
FRONT WHEEL HUB
DISASSEMBLY
ASSEMBLY
FINAL DRIVE CARRIER
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
FIANL DRIVE
DISASSEMBLY
ASSEMBLY
REAR BRAKE
REMOVAL AND INSTALLATION
REAR WHEEL BRAKE
DISASSEMBLY
ASSEMBLY
PARKING BRAKE PAD
REMOVAL
INSTALLATION
PARKING BRAKE CALIPER
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
FRONT SUSPENSION CYLINDER
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
VARIABLE DAMPING SELECTOR VALVE
DISASSEMBLY
ASSEMBLY
REAR SUSPENSION CYLINDER
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
AIR GOVERNOR
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
BRAKE VALVE
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
PARKING BRAKE CHAMBER
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
REAR BRAKE CHAMBER
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
FRONT BRAKE CHAMBER
DISASSEMBLY
ASSEMBLY
SLACK ADJUSTER
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
BRAKE COOLING PUMP
REMOVAL AND INSTALLATION
STEERING,HOIST PUMP
REMOVAL AND INSTALLATION
TORQUE CONVERTER,TRANSMISSION PUMP
REMOVAL AND INSTALLATION
EMERGENCY STEERING MOTOR PUMP
REMOVAL AND INSTALLATION
STEERING VALVE
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
BRAKE CONTROL VALVE (BCV)
REMOVAL AND INSTALLATION
DEMAND VALVE
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
RELIEF VALVE
DISASSEMBLY AND ASSEMBLY
HOIST VALVE
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
STEERING CYLINDER
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
HOIST CYLINDER
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
BODY
REMOVAL
INSTALLATION
CONTROLLER
REMOVAL AND INSTALLATION
AIR CONDITIONER COMPRESSOR
REMOVAL AND INSTALLATION
RECEIVER TANK
REMOVAL AND INSTALLATION
AIR CONDITIONER CONDENSER
REMOVAL AND INSTALLATION

40 MAINTENANCE STANDARD
OUTPUT SHAFT
TURQUE CONVERTER VALVE
TORQUE CONVERTER
TRANSMISSION
ECMV (ELECTRONIC CONTROL MODULATION VALVE)
FRONT AXLE
FRONT AXLE (WITH ABS/ASR) (IF EQUIPPED)
REAR AXLE SUPPORT (HD785-5)
REAR AXLE SUPPORT (HD985-5)
DIFFERENTIAL
FINAL DRIVE (HD785-5)
FINAL DRIVE (HD985-5)
FRONT BRAKE
REAR BRAKE
REAR BRAKE (WITH ABS/ASR) (IF EQUIPPED)
PARKING BRAKE
STEERING LINKAGE
FRONT SUSPENSION CYLINDER
REAR SUSPENSION CYLINDER
PARKING BRAKE CHAMBER
SLACK ADJUSTER
HYDRAULIC PUMP (SAR-160) (FOR TORQUE CONVERTER AND TRANSMISSION)
HYDRAULIC PUMP (SAR4-180+180:FOR STEERING,WORK EQUIPMENT) (SAR4-285+285:FOR BRAKE COOLING)
DEMAND VALVE
CROSS-OVER RELIEF VALVE
HOIST VALVE
STEERING CYLINDER
HOIST CYLINDER

90 OTHERS
ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH MECHANICAL GOVERNOR) (1/3)
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH MECHANICAL GOVERNOR) (2/3)
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH MECHANICAL GOVERNOR) (3/3)
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH ELECTRONIC GOVERNOR) (1/5)
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH ELECTRONIC GOVERNOR) (2/5)
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH ELECTRONIC GOVERNOR) (3/5)
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH ELECTRONIC GOVERNOR) (4/5)
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH ELECTRONIC GOVERNOR) (5/5)
ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (1/2)
ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (2/2)
ELECTRICAL CONTROL SYSTEM
ELECTRICAL CIRCUIT DIAGRAM
AUTOMATIC SHIFT CONTROL SYSTEM
ELECTRICAL CIRCUIT DIAGRAM (1/2)
ELECTRICAL CIRCUIT DIAGRAM (2/2)
AUTOMATIC SUSPENSION SYSTEM
SYSTEM CIRCUIT DIAGRAM (1/2)
SYSTEM CIRCUIT DIAGRAM (2/2)
PAYLOAD METER (PRINTER TYPE) (OP)
ELECTRICAL CIRCUIT DIAGRAM
PAYLOAD METER (CARD TYPE) (OP)
ELECTRICAL CIRCUIT DIAGRAM
PMC SYSTEM (OP)
ELECTRICAL CIRCUIT DIAGRAM (1/2)
ELECTRICAL CIRCUIT DIAGRAM (2/2)
ELECTRICAL CIRCUIT DIAGRAM
ENGINE CONTROL SYSTEM
TRANSMISSION CONTROL SYSTEM
1.ELECTRIC GOVENOR SPECIFICATION
2.MECHANICAL GOVENOR SPECIFICATION
VHMS MACHINE HEALTH DIAGNOSIS SYSTEM (OP)
1.BASIC PRECAUTIONS
1-1.OPERATION,SAFETY,INSPECTON AND MAINTENANCE OF MACHINE
1-2.OPERATION OF MONITORING SYSTEM
1-3.CONSTANT POWER SUPPLY (BATTERY DIRECT POWER SUPPLY)
1-4.PRECAUTIONS AT THE TIME OF TURNING ON THE POWER FOR VHMS
1-5.PRECAUTIONS AT THE TIME OF REPLACING VHMS AND TRANSMISSION CONTROLLER
1-6.OPERATION OF COMMUNICATION (ORB...ORB COMMUNICATION) CONTROLLER
2.OVERVIEW
2-1.APPLICABLE MODEL
2-2.BASIC CONFIGURATION (1) AND (2)
2-3.INSTALLATION DRAWING
3.STRUCTURE AND FUNCTION
3-1.VHMS CONTROLLER
3-2.BLOW-BY GAS SENSOR
3-3.ENGINE OIL TEMPERATURE SENSOR
3-4.AMPLIFIER FOR EXHAUST GAS TEMPERATURE SENSOR
3-5.COMMUNICATION (ORB...ORB COMMUNICATION) CONTROLLER/ANTENNA
4.TROUBLESHOOTING
4-1.TROUBLESHOOTING EQUIPMENT LIST
4-2.CONNECTOR TYPE AND INSTALLATION POSITION
4-3.CONNECTOR ARRANGEMENT DIAGRAM
4-4.ELECTRICAL CIRCUIT DIAGRAM
4-5.ERROR CODE LIST
4-6.STANDARD VALUE TABLE OF ELECTRICAL PARTS
4-7.TROUBLE PHENOMENA LIST
5.DISASSEMBLY AND ASSEMBLY
5-1.REMOVAL AND INSTALLATION OF VHMS CONTROLLER
5-2.REMOVAL AND INSTALLATION OF BLOW-BY GAS SENSOR
5-3.REMOVAL AND INSTALLATION OF BREATHER
5-4.REMOVAL AND INSTALLATION OF ENGINE OIL TEMPERATURE SENSOR
5-5.REMOVAL AND INSTALLATION OF EXHAUST GAS TEMPERATURE SENSOR
5-6.REMOVAL AND INSTALLATION OF EXHAUST GAS TEMPERATURE AMPLIFIER
5-7.REMOVAL AND INSTALLATION OF SNAPSHOT SWITCH
5-8.REMOVAL AND INSTALLATION OF COMMUNICATION (ORB...ORG COMMUNICATION) CONTROLLER AND ANTENNA
6.SETTING OF VHMS CONTROLLER
6-1.SETTING OF VHMS CONTROLLER
6-2.SETTING ITEM
6-3.SETTING FLOW (OUTLINE)
6-4.CHECK OF OPERATION AND PERFORMANCE
6-5.DATA COLLECTION
7.DATA RECOVERY AND TRANSMISSION
7-1.DATA RECOVERY
8.INSPECTION AND MAINTENANCE
8-1.INSPECTION TIMING:INSPECTION AND MAINTENANC TIMING OF MACHINE
8-2.INSPECTION ITEM
9.REPLACEMENT OF PARTS
9-1.WHEN VHMS CONTROLLER IS REPLACED
9-2.WHEN COMMUNICATION CONTROLLER IS REPLACED

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