Komatsu HD1500-8 Shop Manual SEN06990-00

Data Size: 122.79 MB
File Type: PDF
Language: English
Manufacturer: Komatsu
Applicable Machine: Dump Truck
Document: Shop Manual, Error Code, Electrical Schematic, Hydraulic Schematic
Machine Model: Komatsu HD1500-8 Dump Truck
Serial Number: 81228 and up
Book Number: SEN06990-00
Page: 3068 Pages

List Contents:

00 Index and Foreword
Foreword, Safety, Basic Information
How to Read the Shop Manual
Safety Notice for Operation
Precautions to Prevent Fire
Procedures If Fire Occurs
Precautions When You Dispose of Waste Materials
Engine Technology to Conform Exhaust Gas Emission
Precautions When You Handle Hydraulic Equipment
Precautions When You Disconnect and Connect Pipings
Precautions When You Handle Electrical Equipment
Precautions When You Handle Fuel System Equipment
Precautions When You Handle Intake System Equipment
Practical Use of KOMTRAX
Disconnect and Connect Push-Pull Type Coupler
Precautions for Disconnection and Connection of Connectors
How to Disconnect and Connect Deutsch Connector
How to Disconnect and Connect Slide Lock Type Connector
How to Disconnect and Connect Connector with Lock to Pull
How to Disconnect and Connect Connector with Lock to Push
How to Disconnect and Connect Connector with Housing to Rotate
HOW TO READ ELECTRICAL WIRE CODE
Explanation of Terms for Maintenance Standard
Standard Tightening Torque Table
Conversion Table
Abbreviation List
01 Specifications
Table of Contents
Specifications
Specification Drawing
Specifications
Weight Table
FUEL, COOLANT, AND LUBRICATING OIL
10 Structure and Function
Table of Contents
Boot-up System
LAYOUT DRAWING OF BOOT-UP SYSTEM
System Operating Lamp System
Battery Disconnect Switch
STARTING MOTOR DISCONNECT SWITCH
Engine Shutdown Secondary Switch
EXTERNAL POWER SUPPLY ENGINE PREHEATER
Engine System
LAYOUT DRAWING OF ENGINE SYSTEM
Engine Control System
Component Parts of Engine System
Cooling System
LAYOUT DRAWING OF COOLING SYSTEM
FAN SPEED CONTROL SYSTEM OF FAN CLUTCH
Component Parts of Cooling System
Control System
LAYOUT DRAWING OF CONTROL SYSTEM
LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH MOBILE COMMUNICATION TERMINAL)
RETARDER AND HOIST CONTROL SYSTEM
Machine Monitor System
Rearview Monitor System
KOMTRAX Plus System
Payload Meter System
Drowsiness Detection System
Component Parts of Control System
Hydraulic System
LAYOUT DRAWING OF HYDRAULIC SYSTEM
COMPONENT PARTS OF HYDRAULIC SYSTEM
Power Train System
LAYOUT DRAWING OF POWER TRAIN SYSTEM
Transmission Control System
Gear Shift Control System
Direction Control System
Komatsu Traction Control System (KTCS)
Travel Speed Limitation System
REAR AXLE OIL FILTRATION SYSTEM
COMPONENT PARTS OF POWER TRAIN SYSTEM
Work Equipment System
Work Equipment Control
Hoist Control
Component Parts of Work Equipment System
Steering System
LAYOUT DRAWING OF STEERING SYSTEM
FUNCTION OF STEERING SYSTEM
Steering Column
Steering Linkage
COMPONENT PARTS OF STEERING SYSTEM
Brake System
LAYOUT DRAWING OF BRAKE SYSTEM
Retarder Control
ARSC System
Component Parts of Brake System
Auto-Greasing System
LAYOUT DRAWING OF AUTO-GREASING SYSTEM
AUTO-GREASING SYSTEM DIAGRAM
FUNCTION OF AUTO-GREASING SYSTEM
GREASE REFILL AUTOMATIC STOP SYSTEM
Auto-Greasing System
SERVICE CENTER
LAYOUT DRAWING OF SERVICE CENTER
FUNCTION OF SERVICE CENTER
Undercarriage and Frame
REAR AXLE SUPPORT
Suspension
Front Suspension
Rear Suspension
Front Suspension Cylinder
Rear Suspension Cylinder
Work Equipment
STRUCTURE OF WORK EQUIPMENT
CAB Related Parts
ROPS CAB
CAB Mount
Lifting System
Power Ladder System
20 Standard Value Table
Table of Contents
Standard Value Table for Engine
STANDARD VALUE TABLE FOR ENGINE: HD1500-8
Standard Value Table for Machine
STANDARD VALUE TABLE FOR MACHINE: HD1500-8
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE
30 Testing and Adjusting
Table of Contents
Precautions Before Work
Related Information on Testing and Adjusting
TOOLS TO TEST AND ADJUST
Engine and Cooling System
TEST ENGINE SPEED
TEST EXHAUST GAS COLOR
TEST BLOWBY PRESSURE
TEST FUEL PRESSURE
BLEED AIR FROM FUEL CIRCUIT
TEST TORQUE CONVERTER STALL SPEED
Power Train
TEST POWER TRAIN OIL PRESSURE
ADJUST TRANSMISSION INPUT SHAFT SPEED SENSOR
ADJUST TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR
ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR
CHECK AFTER ADJUSTING TRANSMISSION SPEED SENSOR
FLUSH TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT
CLEAN FINAL DRIVE CASE MAGNET
MOVE MACHINE WITH ELECTRICAL SYSTEM PROBLEMS
STEERING SYSTEM
TEST STEERING CIRCUIT OIL PRESSURE
TEST STEERING CYLINDER PRESSURE
BLEED AIR FROM STEERING CYLINDER CIRCUIT
Brake System
RELEASE PRESSURE IN BRAKE ACCUMULATOR CIRCUIT
TEST WHEEL BRAKE OIL PRESSURE
TEST AND ADJUST BRAKE ACCUMULATOR PRESSURE
TEST AND PRESSURIZE BRAKE ACCUMULATOR WITH NITROGEN GAS
PROCEDURE TO RELEASE NITROGEN GAS WHEN DISPOSING ACCUMULATOR
TEST BRAKE PERFORMANCE
BLEED AIR FROM BRAKE CIRCUIT
TEST PARKING BRAKE OIL PRESSURE
RELEASE PARKING BRAKE MANUALLY
TEST THE AMOUNT OF WHEEL BRAKE DISC WEAR
Hydraulic System
TEST HOIST CIRCUIT OIL PRESSURE
TEST HOIST CYLINDER SUPPLY PRESSURE
TEST OIL PRESSURE OF HOIST EPC VALVE CIRCUIT
TEST AND ADJUST FRONT SUSPENSION CYLINDER
TEST AND ADJUST REAR SUSPENSION CYLINDER
BLEED AIR FROM HYDRAULIC CIRCUIT
CALIBRATION OF LADDER POSITION
Work Equipment
TEST AND ADJUST DUMP BODY POSITIONER SENSOR
LOWER THE DUMP BODY MANUALLY
LIFT THE DUMP BODY MANUALLY
LIFT THE DUMP BODY WITH BUDDY SYSTEM
CAB Related Parts
ADJUST STEERING WHEEL TILT LOCK LEVER
ADJUST RATTLING OPERATOR'S SEAT
ADJUST CLEARANCE OF ESCAPE DOOR
LIFTING SYSTEM
BLEED AIR FROM POWER LADDER CYLINDER
Electrical System
SET AND ADJUST EACH EQUIPMENT
SET AND OPERATE OF MACHINE MONITOR
START UP KOMTRAX TERMINAL
STOP USE OF KOMTRAX TERMINAL
STOP USE OF KOMTRAX TERMINAL (MACHINE WITH MOBILE COMMUNICATION TERMINAL)
SETTING DEFAULT OF KOMTRAX Plus CONTROLLER
SETTING DEFAULT OF WIRELESS LAN MODEM
DOWNLOAD KOMTRAX Plus CONTROLLER DATA
ADJUST WHEN KOMTRAX Plus CONTROLLER IS REPLACED
ADJUST WHEN WIRELESS LAN MODEM IS REPLACED
SETTING OF MOBILE COMMUNICATION TERMINAL
Set Driver Status Monitor
VOLTAGE CIRCUIT OF ENGINE CONTROLLER WORK
BATTERY DISCONNECT SWITCH WORK
BATTERY DISCONNECT SWITCH WORK (MACHINE WITH MOBILE COMMUNICATION TERMINAL)
TEST DIODES
Pm Clinic
Pm CLINIC SERVICE
PERFORM QUICK Pm
40 Troubleshooting
Table of Contents
Precautions Before Work
Related Information to Troubleshooting
General Troubleshooting Points
Sequence of Events in Troubleshooting
CHECKS BEFORE TROUBLESHOOTING
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING
TESTING IN ACCORDANCE WITH TESTING PROCEDURE
ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION
PROCEDURE FOR TESTING AND TROUBLESHOOTING
SYMPTOM AND TROUBLESHOOTING NUMBERS
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE
CONNECTORS LIST AND LAYOUT
CONNECTOR CONTACT IDENTIFICATION
T-Branch Box and T-Branch Adapter Table
FUSE LOCATION TABLE
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR
Procedure to Make Harness Checker on Machine Monitor LCD Unit
FAILURE CODES TABLE
Troubleshooting by Failure Code (Display of Code)
FAILURE CODE [1500L0]
FAILURE CODE [15B0NX]
FAILURE CODE [15F0KM]
FAILURE CODE [15F0MB]
FAILURE CODE [15F7KM]
FAILURE CODE [15G0MW]
FAILURE CODE [15G7KM]
FAILURE CODE [15H0MW]
FAILURE CODE [15J0MW]
FAILURE CODE [15K0MW]
FAILURE CODE [15L0MW]
FAILURE CODE [15M0MW]
FAILURE CODE [15N0MW]
FAILURE CODE [15SBL1]
BLEED AIR FROM POWER LADDER CYLINDER
Electrical System
SET AND ADJUST EACH EQUIPMENT
SET AND OPERATE OF MACHINE MONITOR
START UP KOMTRAX TERMINAL
STOP USE OF KOMTRAX TERMINAL
STOP USE OF KOMTRAX TERMINAL (MACHINE WITH MOBILE COMMUNICATION TERMINAL)
SETTING DEFAULT OF KOMTRAX Plus CONTROLLER
SETTING DEFAULT OF WIRELESS LAN MODEM
DOWNLOAD KOMTRAX Plus CONTROLLER DATA
ADJUST WHEN KOMTRAX Plus CONTROLLER IS REPLACED
ADJUST WHEN WIRELESS LAN MODEM IS REPLACED
SETTING OF MOBILE COMMUNICATION TERMINAL
Set Driver Status Monitor
VOLTAGE CIRCUIT OF ENGINE CONTROLLER WORK
BATTERY DISCONNECT SWITCH WORK
BATTERY DISCONNECT SWITCH WORK (MACHINE WITH MOBILE COMMUNICATION TERMINAL)
TEST DIODES
Pm Clinic
Pm CLINIC SERVICE
PERFORM QUICK Pm
40 Troubleshooting
Table of Contents
Precautions Before Work
Related Information to Troubleshooting
General Troubleshooting Points
Sequence of Events in Troubleshooting
CHECKS BEFORE TROUBLESHOOTING
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING
TESTING IN ACCORDANCE WITH TESTING PROCEDURE
ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION
PROCEDURE FOR TESTING AND TROUBLESHOOTING
SYMPTOM AND TROUBLESHOOTING NUMBERS
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE
CONNECTORS LIST AND LAYOUT
CONNECTOR CONTACT IDENTIFICATION
T-Branch Box and T-Branch Adapter Table
FUSE LOCATION TABLE
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR
Procedure to Make Harness Checker on Machine Monitor LCD Unit
FAILURE CODES TABLE
Troubleshooting by Failure Code (Display of Code)
FAILURE CODE [1500L0]
FAILURE CODE [15B0NX]
FAILURE CODE [15F0KM]
FAILURE CODE [15F0MB]
FAILURE CODE [15F7KM]
FAILURE CODE [15G0MW]
FAILURE CODE [15G7KM]
FAILURE CODE [15H0MW]
FAILURE CODE [15J0MW]
FAILURE CODE [15K0MW]
FAILURE CODE [15L0MW]
FAILURE CODE [15M0MW]
FAILURE CODE [15N0MW]
FAILURE CODE [15SBL1]
FAILURE CODE [D1EHKB]
FAILURE CODE [D1EHKY]
FAILURE CODE [D1ENKZ]
FAILURE CODE [D1EPKA]
FAILURE CODE [D1EPKB]
FAILURE CODE [D1EPKY]
FAILURE CODE [D1EQKA]
FAILURE CODE [D1EQKB]
FAILURE CODE [D1EQKY]
FAILURE CODE [D1ERKA]
FAILURE CODE [D1ERKB]
FAILURE CODE [D1ERKY]
FAILURE CODE [D1ESKA]
FAILURE CODE [D1ESKB]
FAILURE CODE [D1ESKY]
FAILURE CODE [D1EWKA]
FAILURE CODE [D1EWKB]
FAILURE CODE [D1EWKY]
FAILURE CODE [D1J0KB]
Failure Code [D5WNKZ]
FAILURE CODE [D5ZHL6]
FAILURE CODE [D862KA]
FAILURE CODE [DAF0KT]
FAILURE CODE [DAF0MB]
FAILURE CODE [DAF0MC]
FAILURE CODE [DAF3KK]
FAILURE CODE [DAF8KB]
FAILURE CODE [DAFDKB]
FAILURE CODE [DAFGMC]
FAILURE CODE [DAFLKA]
FAILURE CODE [DAFLKB]
FAILURE CODE [DAFQKR]
FAILURE CODE [DAQ0KK]
FAILURE CODE [DAQ0KT]
FAILURE CODE [DAQ0MC]
FAILURE CODE [DAQ1KA]
FAILURE CODE [DAQ2KK]
FAILURE CODE [DAQ9KQ]
FAILURE CODE [DAQLKA]
FAILURE CODE [DAQLKB]
FAILURE CODE [DAQQKR]
FAILURE CODE [DAQRKR]
FAILURE CODE [DAQRMA]
FAILURE CODE [DAQV00]
FAILURE CODE [DAQW00]
FAILURE CODE [DAZ9KQ]
FAILURE CODE [DAZQKR]
FAILURE CODE [DB10KT]
FAILURE CODE [DB10MC]
FAILURE CODE [DB11KA]
FAILURE CODE [DB12KK]
FAILURE CODE [DB13KK]
FAILURE CODE [DB19KQ]
FAILURE CODE [DB1LKA]
FAILURE CODE [DB1LKB]
FAILURE CODE [DB1QKR]
FAILURE CODE [DB1QMA]
FAILURE CODE [DB1RKR]
FAILURE CODE [DB1RKR] (For machines equipped with Drowsiness Detection system)
FAILURE CODE [DB2QKR]
FAILURE CODE [DB2QKR] (For machines equipped with Drowsiness Detection system)
FAILURE CODE [DBBUKM]
FAILURE CODE [DBBUKR]
FAILURE CODE [DBP0KM]
FAILURE CODE [DBP0KT]
FAILURE CODE [DBP0NR]
FAILURE CODE [DBP5KP]
FAILURE CODE [DBPLKA]
FAILURE CODE [DBPLKB]
FAILURE CODE [DBPQKR]
FAILURE CODE [DBPRKR]
FAILURE CODE [DBPRMA]
FAILURE CODE [DBPUKR]
FAILURE CODE [DBPVKR]
FAILURE CODE [DBPWKR]
FAILURE CODE [DBPXKR]
FAILURE CODE [DBV0MC]
FAILURE CODE [DBV1KK]
FAILURE CODE [DBV6KB]
FAILURE CODE [DBV7KB]
FAILURE CODE [DBVLKA]
FAILURE CODE [DBVLKB]
FAILURE CODE [DBVQKR]
FAILURE CODE [DBVRKR]
FAILURE CODE [DBVVKR]
FAILURE CODE [DBVWKR]
Failure Code [DCR0MC]
Failure Code [DCR2KK]
Failure Code [DCR8L4]
Failure Code [DCR9KQ]
Failure Code [DCRLKA]
Failure Code [DCRLKB]
Failure Code [DCRQKR]
Failure Code [DCRRKR]
FAILURE CODE [DDAAL6]
FAILURE CODE [DDD7KX]
FAILURE CODE [DDDGL4]
FAILURE CODE [DDDHL4]
FAILURE CODE [DDTHKA]
FAILURE CODE [DDTJKA]
FAILURE CODE [DDTKKA]
FAILURE CODE [DDTLKA]
FAILURE CODE [DDTMKA]
FAILURE CODE [DDTNKA]
FAILURE CODE [DDTPKA]
FAILURE CODE [DDU1KA]
FAILURE CODE [DF10KA]
FAILURE CODE [DF10KB]
FAILURE CODE [DGE5KX]
FAILURE CODE [DGF1KX]
FAILURE CODE [DGR2KB]
FAILURE CODE [DGR2L8]
FAILURE CODE [DGR4KB]
FAILURE CODE [DGR4L8]
FAILURE CODE [DGR6KB]
FAILURE CODE [DGR6L8]
FAILURE CODE [DGREKB]
FAILURE CODE [DGREL8]
FAILURE CODE [DGT1KX]
FAILURE CODE [DHP4KY]
FAILURE CODE [DHP4KZ]
FAILURE CODE [DHP5KY]
FAILURE CODE [DHP5KZ]
FAILURE CODE [DHP6KA]
FAILURE CODE [DHP6KX]
FAILURE CODE [DHP6KY]
FAILURE CODE [DHP6KZ]
FAILURE CODE [DHP7KA]
FAILURE CODE [DHP7KX]
FAILURE CODE [DHP7KY]
FAILURE CODE [DHP7KZ]
FAILURE CODE [DHQ2KX]
FAILURE CODE [DHQ4KX]
FAILURE CODE [DHQ6KX]
FAILURE CODE [DHT5KX]
FAILURE CODE [DHT5L6]
FAILURE CODE [DHT7KX]
FAILURE CODE [DHT7L6]
FAILURE CODE [DHT8KX]
FAILURE CODE [DHT8ZG]
FAILURE CODE [DHU2KX]
FAILURE CODE [DHU3KX]
FAILURE CODE [DHUBKX]
FAILURE CODE [DHUCKX]
FAILURE CODE [DHUDKX]
FAILURE CODE [DHUEKX]
FAILURE CODE [DHUHKX]
FAILURE CODE [DHUJKX]
FAILURE CODE [DHUKKX]
FAILURE CODE [DHULKX]
FAILURE CODE [DHUMKX]
FAILURE CODE [DHUQKX]
FAILURE CODE [DHUSKX]
FAILURE CODE [DJF1KA]
FAILURE CODE [DK30KX]
FAILURE CODE [DK51L5]
FAILURE CODE [DK52KX]
FAILURE CODE [DK53L8]
FAILURE CODE [DK54KX]
FAILURE CODE [DK5VKX]
FAILURE CODE [DK5VMA]
FAILURE CODE [DK60KX]
FAILURE CODE [DKH0KX]
FAILURE CODE [DKH1KX]
FAILURE CODE [DLF1KA]
FAILURE CODE [DLF1LC]
FAILURE CODE [DLF2KA]
FAILURE CODE [DLF2LC]
FAILURE CODE [DLF8LC]
FAILURE CODE [DLF9LC]
FAILURE CODE [DLFKLC]
FAILURE CODE [DLFLLC]
FAILURE CODE [DLT3KA]
FAILURE CODE [DLT3LC]
FAILURE CODE [DX13KY]
FAILURE CODE [DX30K4]
FAILURE CODE [DX30KA]
FAILURE CODE [DX30KB]
FAILURE CODE [DX30KY]
FAILURE CODE [DX30MA]
FAILURE CODE [DX33K4]
FAILURE CODE [DX33KA]
FAILURE CODE [DX33KB]
FAILURE CODE [DX33KY]
FAILURE CODE [DX33MA]
FAILURE CODE [DX37K4]
FAILURE CODE [DX37KA]
FAILURE CODE [DX37KB]
FAILURE CODE [DX37KY]
FAILURE CODE [DX37MA]
FAILURE CODE [DX38K4]
FAILURE CODE [DX38KA]
FAILURE CODE [DX38KB]
FAILURE CODE [DX38KY]
FAILURE CODE [DX38MA]
FAILURE CODE [DX42KZ]
FAILURE CODE [DX43KZ]
FAILURE CODE [DXH1KA]
FAILURE CODE [DXH1KB]
FAILURE CODE [DXH1KY]
FAILURE CODE [DXH2KA]
FAILURE CODE [DXH2KB]
FAILURE CODE [DXH2KY]
FAILURE CODE [DXH3KA]
FAILURE CODE [DXH3KB]
FAILURE CODE [DXH3KY]
FAILURE CODE [DXH4KA]
FAILURE CODE [DXH4KB]
FAILURE CODE [DXH4KY]
FAILURE CODE [DXH5KA]
FAILURE CODE [DXH5KB]
FAILURE CODE [DXH5KY]
FAILURE CODE [DXH6KA]
FAILURE CODE [DXH6KB]
FAILURE CODE [DXH6KY]
FAILURE CODE [DXH7KA]
FAILURE CODE [DXH7KB]
FAILURE CODE [DXH7KY]
FAILURE CODE [DXHHKA]
FAILURE CODE [DXHHKB]
FAILURE CODE [DXHHKY]
FAILURE CODE [DY30MA]
FAILURE CODE [DY30MC]
FAILURE CODE [DY30ME]
FAILURE CODE [DY32MC]
FAILURE CODE [F9A1KK]
FAILURE CODE [F9A2KK]
FAILURE CODE [F9ALKA]
FAILURE CODE [F9ALKB]
FAILURE CODE [F9AQKR]
FAILURE CODE [F9ARKR]
FAILURE CODE [F9AUKA]
FAILURE CODE [DX13KY]
FAILURE CODE [DX30K4]
FAILURE CODE [DX30KA]
FAILURE CODE [DX30KB]
FAILURE CODE [DX30KY]
FAILURE CODE [DX30MA]
FAILURE CODE [DX33K4]
FAILURE CODE [DX33KA]
FAILURE CODE [DX33KB]
FAILURE CODE [DX33KY]
FAILURE CODE [DX33MA]
FAILURE CODE [DX37K4]
FAILURE CODE [DX37KA]
FAILURE CODE [DX37KB]
FAILURE CODE [DX37KY]
FAILURE CODE [DX37MA]
FAILURE CODE [DX38K4]
FAILURE CODE [DX38KA]
FAILURE CODE [DX38KB]
FAILURE CODE [DX38KY]
FAILURE CODE [DX38MA]
FAILURE CODE [DX42KZ]
FAILURE CODE [DX43KZ]
FAILURE CODE [DXH1KA]
FAILURE CODE [DXH1KB]
FAILURE CODE [DXH1KY]
FAILURE CODE [DXH2KA]
FAILURE CODE [DXH2KB]
FAILURE CODE [DXH2KY]
FAILURE CODE [DXH3KA]
FAILURE CODE [DXH3KB]
FAILURE CODE [DXH3KY]
FAILURE CODE [DXH4KA]
FAILURE CODE [DXH4KB]
FAILURE CODE [DXH4KY]
FAILURE CODE [DXH5KA]
FAILURE CODE [DXH5KB]
FAILURE CODE [DXH5KY]
FAILURE CODE [DXH6KA]
FAILURE CODE [DXH6KB]
FAILURE CODE [DXH6KY]
FAILURE CODE [DXH7KA]
FAILURE CODE [DXH7KB]
FAILURE CODE [DXH7KY]
FAILURE CODE [DXHHKA]
FAILURE CODE [DXHHKB]
FAILURE CODE [DXHHKY]
FAILURE CODE [DY30MA]
FAILURE CODE [DY30MC]
FAILURE CODE [DY30ME]
FAILURE CODE [DY32MC]
FAILURE CODE [F9A1KK]
FAILURE CODE [F9A2KK]
FAILURE CODE [F9ALKA]
FAILURE CODE [F9ALKB]
FAILURE CODE [F9AQKR]
FAILURE CODE [F9ARKR]
FAILURE CODE [F9AUKA]
Troubleshooting of Electrical System (E-Mode)
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)
E-2 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING
E-3 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING
E-4 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT
OR FLICKERS)
E-5 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY
E-6 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL
E-7 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL
E-8 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL
E-9 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR
SWITCH DOES NOT OPERATE PROPERLY
E-10 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION
E-11 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL
E-12 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY
E-13 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS
E-14 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY
E-15 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED
E-16 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL
E-17 REARVIEW MONITOR IS NOT DISPLAYED IN CONJUNCTION WITH REVERSE WHEN THE
CONSTANT DISPLAY SETTING IS DISABLED
E-18 REARVIEW MONITOR REFERENCE LINE IS NOT DISPLAYED WHEN THE REFERENCE LINE
DISPLAY SETTING IS ENABLED
E-19 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL
E-20 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL
E-21 MACHINE MONITOR CANNOT BE OPERATED WHEN STARTING SWITCH IS IN OFF POSITION
E-22 ALARM BUZZER DOES NOT SOUND
E-23 ALARM BUZZER DOES NOT STOP SOUNDING
E-24 AISS FUNCTION DOES NOT OPERATE PROPERLY
E-25 HOIST LEVER DOES NOT OPERATE PROPERLY
E-26 TURN SIGNAL LAMP AND WINKER LAMP (HAZARD LAMP) DO NOT OPERATE PROPERLY
E-27 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS
E-28 SMALL LAMP (CLEARANCE LAMP) DOES NOT LIGHT UP
E-29 TAIL LAMP DOES NOT LIGHT UP
E-30 HEADLAMP (LOW BEAM) DOES NOT LIGHT UP
E-31 HEADLAMP (HIGH BEAM) DOES NOT LIGHT UP
E-32 NEITHER (LOW BEAM) NOR (HIGH BEAM) HEADLAMPS LIGHTS UP
E-33 HIGH BEAMS DO NOT LIGHT UP WHILE PASSING SWITCH IS OPERATED
E-34 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY
E-35 DATA DOWNLOADING BY USING WIRELESS LAN CAN NOT BE PERFORMED
E-36 KomVision MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS
E-37 KomVision MONITOR IMAGES ARE NOT DISPLAYED CLEARLY
E-38 KomVision MONITOR BRIGHTNESS CANNOT BE ADJUSTED
E-39 NIGHT LIGHTING LAMP OF KomVision MONITOR IS ABNORMAL
E-40 PART OF THE CAMERA IMAGE IS NOT DISPLAYED ON THE KomVision MONITOR
E-41 IMAGE ON KomVision MONITOR IS NOT DISPLAYED PROPERLY AFTER CALIBRATION
E-42 EXTERNAL POWER SUPPLY ENGINE OIL PAN HEATER DOES NOT OPERATE
E-43 EXTERNAL POWER SUPPLY BRAKE TANK HEATER DOES NOT OPERATE
E-44 EXTERNAL POWER SUPPLY TRANSMISSION OIL PAN HEATER DOES NOT OPERATE
E-45 EXTERNAL POWER SUPPLY HYDRAULIC TANK HEATER DOES NOT OPERATE
E-46 BUZZER DOES NOT SOUND WHEN POWER LADDER IS OPERATED
E-47 POWER LADDER PUMP DOES NOT OPERATE
E-48 Cannot Access to the Setting Screen of the Mobile Communication Terminal
E-49 CANNOT LOG IN TO THE SETTING SCREEN OF THE MOBILE COMMUNICATION TERMINAL
BECAUSE THE LOG IN PASSWORD IS UNKNOWN
E-50 KOMTRAX Plus Controller is Not Found
E-51 KOMTRAX Plus Controller Does Not Become Active
E-52 Communication Failure Occurs Between Mobile Communication Terminal and KOMTRAX Plus
Server
E-53 Data is Not Sent to KOMTRAX Plus Server
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)
FAILURE MODE AND CAUSE TABLE
H-1 MACHINE DOES NOT START
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE HUNTS)
H-3 LOCKUP IS NOT RELEASED
H-4 ABNORMALLY STRONG SHOCKS RESULT FROM STARTING OF MACHINE AND GEAR
SHIFTING
H-5 GEAR IS NOT UPSHIFTED
H-6 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN LOCKUP DRIVE MODE
AT ALL GEAR SPEEDS
H-7 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN TORQUE CONVERTER
DRIVE MODE
H-8 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING AT PARTICULAR GEAR
SPEED
H-9 LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED
H-10 OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH
H-11 OIL PRESSURE OF TORQUE CONVERTER IS LOW
H-12 STEERING WHEEL IS HEAVY TO OPERATE
H-13 STEERING WHEEL CANNOT BE OPERATED
H-14 STEERING WHEEL WAGGLES
H-15 FRONT BRAKE DOES NOT APPLY SUFFICIENTLY
H-16 REAR BRAKE DOES NOT APPLY SUFFICIENTLY
H-17 DUMP BODY RISING SPEED IS LOW
H-18 HYDRAULIC DRIFT OF DUMP BODY IS LARGE
H-19 DUMP BODY DOES NOT MOVE
H-20 FAN SPEED IS UNUSUAL (EXCESSIVELY HIGH OR LOW, OR FAN STOPS)
H-21 UNUSUAL NOISE IS HEARD FROM AROUND FAN
H-22 POWER LADDER DOES NOT MOVE OR ITS SPEED IS LOW
50 Disassembly and Assembly
Table of Contents
Precautions Before Work
Related Information on Disassembly and Assembly
HOW TO READ THIS MANUAL
COATING MATERIALS LIST
SPECIAL TOOL LIST
DIAGRAMS OF SPECIAL TOOLS
Engine and Cooling System
REMOVE AND INSTALL RADIATOR ASSEMBLY
REMOVE AND INSTALL OIL COOLER ASSEMBLY
REMOVE AND INSTALL ENGINE ASSEMBLY
REMOVE AND INSTALL DAMPER ASSEMBLY
DISASSEMBLE AND ASSEMBLE OF DAMPER ASSEMBLY
DISASSEMBLE AND ASSEMBLE OF RADIATOR ASSEMBLY
POWER TRAIN
REMOVE AND INSTALL FRONT DRIVE SHAFT
REMOVE AND INSTALL REAR DRIVE SHAFT ASSEMBLY
REMOVE AND INSTALL TORQUE CONVERTER AND TRANSMISSION ASSEMBLY
DISCONNECT AND CONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY
DISASSEMBLE AND ASSEMBLE OF TORQUE CONVERTER AND PTO ASSEMBLY
DISASSEMBLE AND ASSEMBLE OF TRANSMISSION ASSEMBLY
REMOVE AND INSTALL DIFFERENCIAL ASSEMBLY
DISASSEMBLE AND ASSEMBLE OF DIFFERENTIAL ASSEMBLY
REMOVE AND INSTALL FINAL DRIVE CARRIER ASSEMBLY
DISASSEMBLE AND ASSEMBLE OF FINAL DRIVE CARRIER ASSEMBLY
Brake System
REMOVE AND INSTALL FRONT WHEEL HUB AND BRAKE ASSEMBLY
DISASSEMBLE AND ASSEMBLE OF FRONT WHEEL HUB AND BRAKE ASSEMBLY
REMOVE AND INSTALL FINAL DRIVE AND REAR BRAKE ASSEMBLY
DISASSEMBLE AND ASSEMBLE OF FINAL DRIVE AND REAR BRAKE ASSEMBLY
Steering System
REMOVE AND INSTALL STEERING VALVE ASSEMBLY
REMOVE AND INSTALL O-RING OF STEERING VALVE ASSEMBLY
REMOVE AND INSTALL STEERING CYLINDER ASSEMBLY
DISASSEMBLE AND ASSEMBLE OF STEERING CYLINDER ASSEMBLY
Undercarriage and Frame
REMOVE AND INSTALL FRONT WHEEL ASSEMBLY
REMOVE AND INSTALL REAR WHEEL ASSEMBLY
REMOVE AND INSTALL FRONT SUSPENSION CYLINDER ASSEMBLY
DISASSEMBLE AND ASSEMBLE OF FRONT SUSPENSION CYLINDER ASSEMBLY (CYLINDER
WITH BUFFER RING)
REMOVE AND INSTALL KING PIN
REMOVE AND INSTALL REAR SUSPENSION CYLINDER ASSEMBLY
DISASSEMBLE AND ASSEMBLE OF REAR SUSPENSION CYLINDER ASSEMBLY (CYLINDER
WITH BUFFER RING)
INSTALL AUTOMATIC FIRE EXTINGUISHER
Hydraulic System
REMOVE AND INSTALL FLOW AMPLIFIER VALVE ASSEMBLY
REMOVE AND INSTALL O-RING of FLOW AMPLIFIER VALVE ASSEMBLY
REMOVE AND INSTALL HOIST VALVE ASSEMBLY
REMOVE AND INSTALL HOIST CYLINDER HEAD ASSEMBLY
DISASSEMBLE AND ASSEMBLE OF HOIST CYLINDER ASSEMBLY
Work Equipment
REMOVE AND INSTALL DUMP BODY ASSEMBLY
CAB Related Parts
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY
REMOVE AND INSTALL OPERATOR'S SEAT ASSEMBLY
REMOVE AND INSTALL SEAT BELT
Electrical System
REMOVE AND INSTALL RETARDER AND HOIST CONTROLLER ASSEMBLY
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY
REMOVE AND INSTALL KOMTRAX PLUS CONTROLLER ASSEMBLY
REMOVE AND INSTALL MOBILE COMMUNICATION TERMINAL
REMOVE AND INSTALL DC-DC CONVERTER
REMOVE AND INSTALL MOBILE COMMUNICATION TERMINAL WIRING HARNESS
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY
REMOVE AND INSTALL REARVIEW CAMERA
REMOVE AND INSTALL KomVision CAMERA
REMOVE AND INSTALL KomVision RADAR
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY
REMOVE AND INSTALL WIRELESS LAN UNIT ASSEMBLY
Remove and Install Driver Status Monitor
Remove and Install Translator Controller
Remove and Install Drowsiness Detection Camera
Remove and Install Drowsiness Alarm Buzzer
Remove and Install Drowsiness Detection Wiring Harness
60 Maintenance Standard
Table of Contents
Engine and Cooling System
MAINTENANCE STANDARD OF ENGINE MOUNT
MAINTENANCE STANDARD OF OUTPUT SHAFT
MAINTENANCE STANDARD OF FRONT BRAKE COOLING REMOTE MOTOR
MAINTENANCE STANDARD OF REAR BRAKE COOLING REMOTE MOTOR
Power Train
MAINTENANCE STANDARD OF DRIVE SHAFT
MAINTENANCE STANDARD OF TORQUE CONVERTER AND TRANSMISSION MOUNT
MAINTENANCE STANDARD OF TORQUE CONVERTER AND PTO
MAINTENANCE STANDARD OF TORQUE CONVERTER VALVE
MAINTENANCE STANDARD OF TORQUE CONVERTER REGULATOR VALVE
MAINTENANCE STANDARD OF TRANSMISSION
MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE
MAINTENANCE STANDARD OF FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED
CLUTCH ECMV
MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV
MAINTENANCE STANDARD OF TRANSMISSION LUBRICATION SELECTOR VALVE
MAINTENANCE STANDARD OF FRONT AXLE
MAINTENANCE STANDARD OF REAR AXLE
MAINTENANCE STANDARD OF DIFFERENTIAL
MAINTENANCE STANDARD OF FINAL DRIVE
Steering System
MAINTENANCE STANDARD OF STEERING COLUMN
MAINTENANCE STANDARD OF STEERING CONTROL LINKAGE
MAINTENANCE STANDARD OF STEERING CYLINDER
Brake System
MAINTENANCE STANDARD OF FRONT SLACK ADJUSTER
MAINTENANCE STANDARD OF REAR SLACK ADJUSTER
MAINTENANCE STANDARD OF FRONT BRAKE AND PARKING BRAKE
MAINTENANCE STANDARD OF REAR BRAKE AND PARKING BRAKE
Undercarriage and Frame
MAINTENANCE STANDARD OF FRONT SUSPENSION CYLINDER
MAINTENANCE STANDARD OF REAR SUSPENSION CYLINDER
MAINTENANCE STANDARD OF REAR AXLE SUPPORT
Hydraulic System
MAINTENANCE STANDARD OF STEERING AND HOIST PUMP
MAINTENANCE STANDARD OF DRIVE PUMP OF HOIST AND FRONT BRAKE COOLING REMOTE
MOTOR
MAINTENANCE STANDARD OF DRIVE PUMP OF REAR BRAKE COOLING REMOTE MOTOR
MAINTENANCE STANDARD OF SERVO VALVE OF DRIVE PUMP OF REAR BRAKE COOLING REMOTE MOTOR
MAINTENANCE STANDARD OF BRAKE CHARGE PUMP
MAINTENANCE STANDARD OF FRONT BRAKE COOLING AND POWER TRAIN TRIPLEX PUMP
MAINTENANCE STANDARD OF FRONT BRAKE COOLING REMOTE PUMP
MAINTENANCE STANDARD OF REAR BRAKE COOLING REMOTE TRIPLEX PUMP
Work Equipment
MAINTENANCE STANDARD OF HOIST CYLINDER
CAB Related Parts
MAINTENANCE STANDARD OF CAB MOUNT
80 Others
Table of Contents
Precautions Before Work
Air Conditioner System
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (7/11)
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (8/11)
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (9/11)
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (10/11)
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (11/11)
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (Only for machine with glass heater, additional heater)
(1/9)
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (Only for machine with glass heater, additional heater)
(2/9)
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (Only for machine with glass heater, additional heater)
(3/9)
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (Only for machine with glass heater, additional heater)
(4/9)
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (Only for machine with glass heater, additional heater)
(5/9)
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (Only for machine with glass heater, additional heater)
(6/9)
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (Only for machine with glass heater, additional heater)
(7/9)
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (Only for machine with glass heater, additional heater)
(8/9)
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (Only for machine with glass heater, additional heater)
(9/9)
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (1/8)
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (2/8)
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (3/8)
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (4/8)
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (5/8)
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (6/8)
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (7/8)
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (8/8)
Electrical Circuit Diagram (Drowsiness Detection System (DDS))
Index